856911 1 Mercury SHAFT

Table 1
Required Tools
Tool Part Number Part Description Qty
C 589-7433 Link Bracket 2
D - Guide Stud
5/8 - 11 by 6 inch 2
E - Loctite 5127 -
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Do not turn the crankshaft or the camshaft while the camshaft gear is removed. If the front gear group is not correctly timed during installation, interference can occur between the pistons and the valves, resulting in damage to the engine.
Note: Refer to Engine News, 27, March 2006, "Sealing and Installing the Flywheel Housing" for more information.
Ensure that the mating surfaces of the flywheel housing and the engine block are clean. Both mating surfaces must be clean, dry, and free of any oil before Tooling (E) is applied.
Illustration 1 g06544602
Apply a 6.0 mm (0.25 inch) bead of Tooling (E) to the mating surface of the flywheel housing. Install seal (46) and O-ring seal (45).
Install Tooling (D) into the cylinder block.
Illustration 2 g06542679
Attach Tooling (C) and a suitable lifting device onto flywheel housing (38). The weight of the flywheel housing is approximately 235 kg (518 lb).
Lift flywheel housing (38) into position onto Tooling (D).
Install bolts (39), bolts (40), bolts (41), bolts (43), and bolts (42).
Install plugs (44).
Tighten plugs (44) to a torque of 70 15 N m (50 11 lb ft).
Remove Tooling (D).
Illustration 3 g06542145
Install bolts (39)
Remove Tooling (C) from flywheel housing (38).
Tighten bolts (39) to a torque of 270 40 N m (200 30 lb ft).
Tighten bolts (40), bolts (41), bolts (42), and bolts (43) to a torque of 135 20 N m (100 15 lb ft).
Install the crankshaft rear seal and wear sleeve.
Install the flywheel.
Illustration 4 g06544959
Install timing bolt (30) in the flywheel. Ensure that the timing pins are installed in each camshaft. Refer to Testing and Adjusting, "Camshaft Timing". Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston".
Illustration 5 g06545119
Use the following procedure to install camshaft drive gear (34) and camshaft drive gear (37).
Clean the taper of the camshaft and the tapered bore of the camshaft gear with a lint free cloth saturated with solvent to remove oil. Clean the parts again with a lint free alcohol wipe to remove any residue. The alcohol wipe will dirty after cleaning the parts. Clean the parts again with a lint free alcohol wipe until no residue is left on the alcohol wipe.Note: The taper of the camshaft and the tapered bore of the camshaft gear must be clean, dry, and free of residue before assembly.
Ensure that the camshaft timing pins and the timing pin for the flywheel are installed.
Place camshaft drive gear (34) and camshaft drive gear (37) in position. Remove the backlash by rotating the gears in the opposite direction of camshaft rotation.Note: For "Standard Rotation" engines, turn the camshaft drive gears COUNTERCLOCKWISE. For "Reverse Rotation" engines, turn the camshaft drive gears CLOCKWISE.
Install bolt (32) and plate (33).
Install bolt (35) and ring (36). Ensure that the hole in the ring is properly seated on the locating pin.
Tighten the bolt to a torque of 360 N m (265 lb ft).
Place a mark on the bolt.
Place a driver against the retaining plate of the camshaft drive gear. Strike the driver with a hammer, three times, or four times.
Tighten the bolt again to a torque of 360 N m (265 lb ft).
Repeat Steps 16h and 16i until the mark has turned at least 90 degrees.
Illustration 6 g06540874
Remove timing pin (26) from the camshaft. Install the timing pin and bolt (25) in the storage positions.
Install seal (24), cover (21), bolts (22), and bolt (23).
Repeat Step 17 and Step 18 for the opposite side camshaft.
Install the gaskets, covers (20), and bolts (19).
Illustration 7 g06540878
Remove the timing bolt from the flywheel. Install plug (27) in the timing hole. Install cover (31), gasket (28), timing bolt (30), and bolt (29).