818998A 2 Mercury SOLENOID ASSEMBLY

Illustration 1 g00906628
Illustration 2 g00906630
Illustration 3 g00906633
Exhaust bypass valve linkage
Closed position
(1) Bolts Apply 5P-3931 Anti-Seize Compound to the threads of the bolts prior to assembly. (2) Bearing (3) Shaft (4) Bolt Apply 5P-3931 Anti-Seize Compound to the threads of the bolts prior to assembly. (5) Cover (6) Stop plate (7) Thrust washer (8) Spacer (9) Cover (10) Shaft (11) Plate (12) Bolt Tighten the bolt to the following torque: ... 14 3 N m (124 27 lb in) (13) Bolt Apply 5P-3931 Anti-Seize Compound to the threads of the bolts prior to assembly. (14) Housing Bore in housing for shaft bushings ... 25.845 0.013 mm (1.0175 0.0005 inch)Outside diameter of shaft bushings ... 25.898 0.013 mm (1.0196 0.0005 inch)Inside diameter of in-line shaft bushings ... 19.806 0.013 mm (0.7798 0.0005 inch)Diameter of shaft ... 19.500 0.013 mm (0.7677 0.0005 inch) (15) Bolt Apply 5P-3931 Anti-Seize Compound to the threads of the bolts prior to assembly. (16) Actuator (17) Nut Torque for nuts ... 25 6 N m (18 4 lb ft) (18) Rod Distance between the center bores of the rod ends ... 242 mm (9.528 inch) (19) Rod Distance between the center bores of the rod ends ... 134.9 mm (5.311 inch) (20) Nut Torque for nuts ... 25 6 N m (18 4 lb ft) (21) Clevis Apply 4C-4030 Thread Lock Compound to the threads. (22) Nut Torque for nut ... 200 20 N m (150 15 lb ft) (23) Inlet port (24) Outlet port (A) Angle Angle for the lever in the fully closed position ... 44.3 degrees (B) Angle Angle for the lever in the fully closed position ... 45 degrees (C) Angle Angle for the lever in the fully closed position ... 44.3 degreesUse the following procedure in order to assemble the exhaust bypass valve and the actuator linkage.
Assemble plate (11) of the exhaust bypass valve to shaft (10). Leave the mounting bolts loose. Assemble thrust washer (7) and stop plate (6). Thickness of thrust washer ... 6.00 0.08 mm (0.2362 0.0031 inch)
Install cover (5).
Fully close plate (11) of the exhaust bypass valve. Tighten mounting bolts (12) to the specified torque. Bend the locking ends upward in order to secure the bolts in position. Install spacer (8) and cover (9) onto shaft (10). Make sure that the shaft can rotate freely.
Install bearings (2) so the lube fitting is accessible. Lubricate the bearings with 5P-0960 Lithium complex grease.
Install shaft (3) with the end that is stamped "W/G END" toward the housing of the exhaust bypass valve.
Install actuator (16) so the inlet port (23) and outlet port (24) are aligned. The ports on the actuator are stamped "Inlet" and "Outlet".
Apply 4C-4030 Thread Lock Compound to the threads of clevis (21). Assemble the clevis on the actuator.
Assemble the levers to shaft (10) of the exhaust bypass valve and to shaft (3). Use the woodruff keys in order to provide proper orientation. Assemble rod (19) so that there is equal thread engagement at each end. Adjust the rod to the specified length. Tighten nuts (20) to the specified torque.
Assemble the lever on the side of the shaft that goes toward the actuator. Use the woodruff key to assemble the lever. Assemble rod (18) so that there is equal thread engagement at each end. Adjust the rod to the specified length. Tighten nuts (17) to the specified torque. Assemble the rod on the clevis. Note: A final adjustment of the linkage is required to ensure that the plate does not contact the housing when the plate is in the closed position. Fully extend the actuator to the closed position. With the plate in contact with the housing, shorten the length of the connecting rod by 2/3 turn. Lock the connecting rod in place.