802962 Mercury SHIFT GEAR

Removing And Fitting Cooling Fan
1. Undo the mounting bolt of the generator clamping plate, Fig. 8-1, and remove the V-belt.
8-1 Note for Refitment:The free movement for tensioning the V-belt is about 10 - 15 mm.2. Remove the generator mounting bolt from the cooling fan housing, Fig. 8-2 and remove the generator with the clamping plate.
8-2 Note for Refitment:Note any shims. Correct any misalignment with the V-belt pulley with shims.3. Unscrew the bolts with recessed hexagonal holes and remove the cooling fan.Fig. 8-4
8-4The cooling fan is fitted in reverse order. Note for Refitment:Tighten bolts with recessed hexagonal holes as specified.Dismantling And Reassembling The Cooling Fan
Dismantling
1. Clamp the pulley of the cooling fan in a vice with protective aluminium jaws and unscrew the clamping bolt.Fig. 8-5
8-52. Remove the fan wheel.3. Drive out the drive shaft from the fan housing with a suitable soft metal drift.Fig. 8-6
8-64. Pull the ball bearing from the drive shaft with a bearing puller.Fig. 8-7
8-75. Remove the retaining ring from the ball bearing and drive the ball bearing out of the housing using a suitable soft metal drift.Reassembling:
6. Fill the new bearing with hot-running bearing grease.7. Press the smaller of the two ball bearings into the fan housing with the closed side facing downwards.Fig. 8-8
8-88. Protect the ball bearing against axial movements in the fan housing with the retaining ring.Fig. 8-9
8-99. Press the larger ball bearing over the drive shaft with the closed side facing the V-belt pulley wheel.Fig. 8-10
8-10 Note for Refitment:Only ball bearings with running-play code C 3 should be used.10. Press the fan shaft (with the ball bearing fitted) home into the fan housing.Fig. 8-11
8-1111. Clamp the cooling fan in a vice by the pulley wheel.12. Fit the rotor wheel, Fig. 8-12 and screw in the clamping bolt. Tighten the clamping bolt as specified. For values see Technical Data.
8-12Removing And Fitting The Oil Cooler (F2L 511)
1. Remove the oil line to oil cooler.Fig. 8-13
8-13 Note for Refitment:Use new copper sealing rings.2. Remove air ducting panel.Fig. 8-14
8-143. Remove the oil cooler together with shield.Fig. 8-15
8-15 Note for Refitment:The bolt marked "A" is a banjo bolt. Use new sealing rings to provide a seal.4. Check and/or replace the oil cooler. Check to ensure a seal (acceptable value) 13 bars.The oil cooler is fitted in reverse order.Removing And Fitting Oil Pump
The front cover has been removed.Removal:
1. Remove crankcase cover.Fig. 8-16
8-162. Remove the four bolts of the crankshaft gear wheel and remove the crankshaft gear wheel.Fig. 8-17
8-173. Remove the oil pump mounting bolt.Fig. 8-18
8-184. Twist the oil pump is such a way that it can be removed complete with the intake pipe.Fitting:
5. Fit the oil pump, insert the mounting bolt with a new copper sealing ring and tighten.6. Fit the crankshaft gear wheel. Note for Refitment:Check that the gear wheel markings line up.Fig. 8-19
8-197. Fit the crankcase cover.Checking The Oil Pump For Wear
1. Dismantle and clean the oil pump.2. Check the oil pump cover for wear. The cover must be absolutely flat.Fig. 8-20
8-203. Measure any axial play by means of a measuring square and / or a sliding caliper and feeler gauge.Fig. 8-21For axial play see Technical Data.
8-214. Measure the backlash of the teeth with a feeler gauge.Fig. 8-22For backlash of the teeth see Technical Data.
8-225. Measure the play in the gear wheels in the housing with the feeler gauge, Fig. 8-23 and compare with the values in the Technical Data.
8-236. Fit the oil pump cover. Tighten the bolts.