42100 Mercury TAB WASHER

Illustration 1 g00476757
(1) Aftercooler inlet line (2) Housing (3) Air inlet from turbocharger (4) Choke plate and shaft (5) Thrust washer Width of groove in shaft for thrust washer ... 6.53 0.10 mm (0.257 0.004 inch) Thickness of thrust washer ... 6.00 0.05 mm (0.236 0.002 inch) (6) Lever (7) Angle for the cross shaft lever (8) Cover assembly with adjusting bolt and locking nut (9) Housing bolts (10) Mounting bolts (11) Rod and rod ends (12) Cross shaft and levers (13) Actuator shaft and indicator (14) Actuator rod and rod ends (15) Angle for the actuator lever (16) Bearings for the cross shaft Bore in bearings for the cross shaft ... 15.880 0.005 mm (0.6252 0.0002 inch) Diameter of surface on shaft for bearings ... 15.739 0.050 mm (0.6196 0.0020 inch)Use the following procedure to assemble the choke and the actuator linkage.
Assemble choke plate (4) to the shaft. Leave mounting bolts (10) loose.
Assemble thrust washer (5). Tighten four housing bolts (9) .Torque ... 47 9 N m (35 7 lb ft)
Fully close the choke plate. Tighten mounting bolts (10) .Torque ... 12 3 N m (9 2 lb ft)
Install housing (2) and gaskets.
After the choke plate and the housing are installed, hold the choke plate in the closed position. Tighten adjusting bolt (8) until the bolt makes contact with the stop plate.
Tighten the adjusting bolt for an additional 90 15 degrees. Tighten the locknut.Torque ... 25 6 N m (18 4 lb ft)Note: Do not allow the adjusting bolt to turn while the locknut is tightened.Use the following procedure to adjust the actuator linkage.
Assemble lever (6) on the shaft. Assemble lever (12) on the choke end of the cross shaft. The choke end is stamped on the cross shaft.
Provide equal thread engagement. Attach the rod and rod ends (11) to the shaft and to the levers.
Adjust the rod length until the choke is in the closed position and the angle for cross shaft lever (7) is 28.0 1.5 degrees from the horizontal position.
Tighten the rod end nuts.Torque ... 26 6 N m (19 4 lb ft)
With actuator shaft (13) in the closed position (100 percent), install the actuator lever. The angle for actuator lever (15) is 68.0 2.5 degrees from the horizontal position.
Install lever (12) on the actuator end of the cross shaft. The actuator end of the cross shaft is not stamped.
Provide equal thread engagement. Attach the rod and rod ends (14) to the actuator lever and to the cross shaft lever.
Completely close the choke. Adjust the rod length until the actuator indicator (pointer) is between the 100 percent and the 97 percent position.Note: The 97 percent position is equal to 2.7 degrees CCW from the 100 percent position.
Tighten the rod end nuts.Torque ... 25 6 N m (18 4 lb ft)Note: The actuator indicator is calibrated in order to show the percentage that the choke plate is opened or closed. The percentage is not the angle. An indicator reading of 2.7 degrees is equal to approximately 2.5 percent.