828631R 2 Mercury SERVICE MANUAL

Table 1
Required Tools
Tool Part Number Part Description Qty
A 238-9586 Camshaft Drive Group 1
B 8B-7548 Push-Puller Tool Group 1
8B-7559 Adapter 2
8B-7561 Step Plate 1
1P-0820 Hydraulic Puller 1
5H-1504 Hard Washer 3
9U-6600 Hand Hydraulic Pump 1
C 138-7573 Link Bracket 2
D - Guide Stud
5/8 - 11 by 6 inch 2
E 169-5464 Quick Cure Primer - Start By:
Remove the starting motors. Refer to Disassembly and Assembly, "Air Starting Motor - Remove". Refer to Disassembly and Assembly, "Electric Starting Motor - Remove and Install".
Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove".
Remove the engine speed sensor. Refer to Disassembly and Assembly, "Engine Speed Sensor - Remove and Install".
Remove the engine speed/timing sensor. Refer to Disassembly and Assembly, "Engine Speed/Timing Sensor - Remove and Install".
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01126909
Remove rear camshaft covers (1).
Remove timing pin (2) from the storage position.
Remove timing bolt (5) from the storage position. Remove cover (3) and plug (4) from the flywheel housing.
Use Tooling (A) to turn the flywheel in order to install timing bolt (5) in the flywheel and timing pin (2) in both camshafts. Refer to Testing and Adjusting, "Camshaft Timing". Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston".
Remove the timing bolt from the flywheel.
Remove the crankshaft rear seal and the wear sleeve. Refer to Disassembly and Assembly, "Crankshaft Rear Seal and Wear Sleeve - Remove".
Illustration 2 g02380117
Remove covers (6) and the gaskets.
Illustration 3 g02380143
Remove bolt (7) and plate (8). Place the three washers from Tooling (B) behind plate (8) and install bolt (7). Install Tooling (B) on camshaft drive gear (9). Apply 51675 kPa (7500 psi) to the puller. Strike the screw on the puller with a hammer until camshaft drive gear (9) is free from the camshaft. Remove Tooling (B) from the camshaft drive gear. Remove camshaft drive gear (9) from the camshaft. Note: Plate (8) must be installed in order to keep camshaft drive gear (9) on the camshaft during the removal procedure.
Illustration 4 g02380144
Remove bolt (10). Remove ring (11).
Illustration 5 g02380146
Place the three washers from Tooling (B) behind plate (8) and install bolt (10). Install Tooling (B) on camshaft drive gear (12). Use Tooling (B) in order to remove camshaft drive gear (12) from the camshaft. Apply 51675 kPa (7500 psi) to the puller. Strike the screw on the puller with a hammer until camshaft drive gear (12) is free from the camshaft. Remove Tooling (B) from the camshaft drive gear. Remove camshaft drive gear (12) from the camshaft. Note: Plate (8) must be installed in order to keep camshaft drive gear (12) on the camshaft during the removal procedure.
Illustration 6 g02380149
Install Tooling (C) and a suitable lifting device on flywheel housing (14). The weight of flywheel housing (14) is approximately 235 kg (518 lb).
Remove two bolts (15) and install Tooling (D). Remove the remaining bolts (15) and remove flywheel housing (14) from the cylinder block.
If necessary, remove plugs (13) from the flywheel housing. Note: Ensure that the rear gear group and the crankshaft are properly protected during the cleaning procedure. Ensure that the bolts are cleaned with a wire brush in order to remove debris or residue. Ensure that the bores for the bolts in the cylinder block are tapped again. Ensure that the bores for the bolts are cleaned in order to remove debris or residue.
After removing flywheel housing (14), clean the mating surface of the cylinder block and the mating surface of the flywheel housing with Tooling (E). If necessary, use a gasket scraper and a solvent in order to remove any residual gasket material. Both mating surfaces must be clean, dry, and free of any oil before installation.