880609 Mercury SENSOR ASSEMBLY

1. Remove the bolt from the automatic advance housing to support (1). Remove support (1).2. Remove bracket (2) and the remainder of the 3/8" cylinder head bolts (3). 3. Do Steps 3a through 3c for the left hand cylinder head only.a) Disconnect clip (4) and move the wiring harness to the side.b) Disconnect ether start line (7) from fittings (5) and (9).c) Remove bolts (8) and remove plate (6) and ether start line (7).4. Do Steps 4a through 4c for the right hand cylinder head only.a) Disconnect the wire assembly from the two sensor units.b) Disconnect the air line to the fuel ratio control.c) Disconnect the two fuel lines. 5. Remove four head bolts (10) from the cylinder head. 6. Install tooling (A). Fasten a hoist to tooling (A).7. Remove the remainder of head bolts (11) from the cylinder head. Remove the cylinder head. Weight of the cylinder head is 90 kg (200 lb.).8. Remove the head gasket from the spacer plate. A new spacer plate gasket and seals must be installed when the cylinder head is removed. See Remove And Install Spacer Plate.Install Cylinder Heads
1. Thoroughly clean the spacer plates and bottom surface of the cylinder heads. Install a new head gasket (1). Do not use any adhesives. A new spacer plate gasket and seals must be installed when the cylinder head is removed. See Remove And Install Spacer Plate. 2. Install tooling (A) on the cylinder head as shown.3. Fasten a hoist to tooling (A) and put the cylinder head in position on the spacer plate. 4. Put clean engine oil on the threads of the cylinder head bolts. Install cylinder head bolts and washers. Tighten the bolts in the following sequence.a) Tighten bolts 2 through 15 in number sequence to a torque of 270 25 N m (200 20 lb.ft.).b) Tighten bolts 2 through 15 in number sequence to a torque of 447 20 N m (330 15 lb.ft.).c) Tighten bolts 2 through 15 in number sequence to a torque of 447 20 N m (330 15 lb.ft.). 5. Install push rods (16) respective to their location.6. Put clean engine oil on the bridge dowels. Install valve bridges (17) in their respective locations on the cylinder head.7. Make an adjustment to the valve bridges. See Bridge Adjustment in Testing And Adjusting. 8. Put rocker shaft assembly (18) in position. Make an alignment of the push rods and rocker arms. Put clean engine oil on the threads of bolts (22) through (25). Install bolts and washers. Tighten the bolts as follows:a) Tighten bolts (22) through (25) in number sequence to a torque of 270 25 N m (200 20 lb.ft.).b) Tighten bolts (22) through (25) in number sequence to a torque of 447 20 N m (330 15 lb.ft.).c) Tighten bolts (22) through (25) in number sequence again to a torque of 447 20 N m (330 15 lb.ft.). 9. Install support (19) and bracket (20). Tighten the bolts finger tight. Tighten the bolt that holds support (19) to the automatic timing advance housing and bracket (20) to the fuel injection pump housing to standard torque.10. Install the remainder of the 3/8" head bolts (21). Tighten all of the 3/8" head bolts (21) to a torque of 43 7 N m (32 5 lb.ft.). 11. Do Steps 11a through 11c for the left hand cylinder head only.a) Install plate (28) and ether start line (27).b) Connect ether start line to fittings (26) and (29).c) Fasten wire harness clip (30) to the cylinder head.12. Do Steps 12a through 12c for the right hand cylinder head only.a) Connect the wire assembly for the two sensor units.b) Connect the air line to the fuel ratio control.c) Connect the two fuel lines.13. Make an adjustment of the valves to have a clearance of 0.38 mm (0.15 in.) for intake and 0.76 mm (0.30 in.) for exhaust valves. See Valve Clearance Setting in Testing And Adjusting.END BY:a) install water temperature regulatorsb) install turbochargerc) install mufflerd) install aftercooler