898103T15 Mercury TANK, Reservoir

start by:a) remove spacer platesb) remove piston 1. Make an adjustment of the legs on tool (A) for the length of the cylinder liner. Be careful not to damage cooling tube at the bottom of the cylinder liner. 2. Turn the nut on tool (A) until cylinder liner (1) is free of the cylinder block. 3. Remove seals (3) and filler band (2) from the cylinder liner.Install Cylinder Liners
1. Install the gasket and spacer plate.2. Clean the cylinder liners and liner bores in the cylinder block. 3. Install the cylinder liners (1) in the cylinder block without seals or bands. 4. Check the cylinder liner projection as follows: a) Install four bolts (4) and washers from tooling (A) around each cylinder liner as shown. Tighten the bolts evenly to a torque of 70 lb.ft. (95 N m).b) Install plate (3), crossbar (6), plates (5) and bolts (2) and washers from tooling (A). Be sure the crossbar is in position at the center of the liner and the liner surface is clean. Tighten bolts (1) evenly to a torque of 50 lb.ft. (70 N m).c) Check the distance from the bottom edge of crossbar (6) to the top edge of the spacer plate. The distance on each end of the crossbar must be the same.d) Check the liner projection with tool (B) at four locations around the liner. Liner projection must be .001 to .006 in. (0.03 to 0.15 mm). The difference between the four measurements on the same liner must not be more than .002 in. (0.05 mm). The difference between liner projection for liners next to each other must not be more than .002 in. (0.05 mm). If the liner is turned in the cylinder block it can make a difference in liner projection.5. If the liner projection is not .001 to .006 in. (0.03 to 0.15 mm), check the thickness of the following parts: a) Spacer plate (X): .338 .001 in. (8.59 0.03 mm)b) Spacer plate gasket (Y): .008 .001 in. (0.20 0.03 mm)[All surfaces must be clean and dry when gaskets are installed].c) Cylinder liner flange (Z): .3500 .0008 in. (8.890 0.020 mm) The cylinder liner projection can be made variable by a change of the counterbore in the block. See SPECIAL INSTRUCTION Form FMO55228. Shims are available for the adjustment of the liner projection. See PROJECTION OF CYLINDER LINER in TESTING AND ADJUSTING for the shim thickness and part number. 6. Put a mark (7) on the cylinder liners and block so the liners can be installed in same position.7. Remove tooling (A) and tool (B). Remove one liner. 8. Put liquid soap on seals (8), grooves of the liner and the bore of the block. Install seal on the cylinder liner.9. Put the filler band (9) in clean SAE 30 oil for a short time. Install the filler band on the liner. 10. Install the liner immediately after the filler band is installed. Make sure the mark on liner is in alignment with the mark on the block. Use tooling (C) to push the liner into position.11. Do Steps 7 through 10 for the remainder of the liners.end by:a) install pistons