828030A 4 Mercury TILL HANDLE KIT

Illustration 1 g01193083
Right Side View
(1) Cylinder head studs Install the cylinder head studs with the following procedure:
Coat the lower half of each stud with 1.5 mm (0.06 inch) thick coating of 4C-4774 Water and Temperature Resistant Grease.
Thoroughly clean the top of the cylinder block.
Install the cylinder head studs. Tighten the cylinder head studs to the following torque. ... 100 20 N m (75 15 lb ft)
Apply a bead of sealant at the top of the block around each stud. This will ensure that the counterbore is filled with grease.
Coat the upper half of each stud with 1.5 mm (0.06 inch) thick coating of 4C-4774 Water and Temperature Resistant Grease. (2) The dowels protrude from the front face of the cylinder block at the following distance. ... 8.0 1.0 mm (0.32 0.04 inch) (3) The dowels protrude from the rear face of the cylinder block at the following distance. ... 20.0 1.0 mm (0.79 0.04 inch) (4) The dowels protrude from the front face of the cylinder block at the following distance. 7N-2328 Dowel ... 20.0 1.0 mm (0.79 0.04 inch)
Illustration 2 g01193086
Front view of cylinder block
(5) The dowels protrude above the cylinder block face at the following distance. ... 8.0 1.0 mm (0.32 0.04 inch) (6) The dowels protrude above the cylinder block face at the following distance. ... 60.0 1.0 mm (2.36 0.04 inch)Apply 4C-4774 Water and Temperature Resistant Grease to the dowel before the head is assembled. (7) Bore in the block for main bearings ... 265.000 0.020 mm (10.4330 0.0008 inch) 1.00 mm (0.040 inch) oversize ... 266.000 0.020 mm (10.4724 0.0008 inch) 2.00 mm (0.080 inch) oversize ... 267.000 0.020 mm (10.5118 0.0008 inch) (8) The centerline of the crankshaft bearing bore to the top surface of the cylinder block ... 946.00 mm (37.244 inch)Procedure for tightening the main bearings
Torque studs (9) in the cylinder block again. Torque for the studs ... 100 20 N m (75 15 lb ft)
Assemble the main bearing cap and the washer. Hand tighten the nut.
Assemble the side bolts on the side of the cap with the tab slot. Tighten the side bolts by hand. Lubricate the washer face and the threads with engine oil before assembly.
Start at the front face of the block. Tighten the side bolts on the side of the cap with the tab slot to the following torque. ... 215 40 N m (160 30 lb ft)
Simultaneously tension each pair of the studs with either of the following tensioners: 207-5034 Stud Tensioner Tool Gp ... 65000 2400 kPa (9425 350 psi) 191-5320 Stud Tensioner Tool Gp ... 111500 3950 kPa (16200 575 psi)Tighten the nuts by hand. Slowly release the pressure.
Repeat Step 5.
Tighten the side bolts on the side of the cap opposite the tab slot hand tight. Lubricate the washer face and the threads with engine oil before assembly.
Start at the front face of the block. Tighten the side bolts on the side of the cap opposite the tab slot to the following torque. ... 215 40 N m (160 30 lb ft)
Start at the front face of the block. Tighten the side bolts on the side of the cap with the tab slot to the following torque. ... 1825 175 N m (1340 130 lb ft)
Start at the front face of the block. Tighten the side bolts on the side of the cap opposite the tab slot to the following torque. ... 1825 175 N m (1340 130 lb ft) (11) Width of main bearing cap ... 499.95 0.03 mm (19.683 0.001 inch)Width of cylinder block for main bearing cap ... 500.00 0.05 mm (19.685 0.002 inch)Clearance between the sides of the main bearing cap and the cylinder block ... 0.03 to 0.13 mm (0.001 to 0.005 inch)
Illustration 3 g01193094
Main bearing cap
(12) The dowel protrudes from the main bearing cap at the following distance. ... 10.0 0.5 mm (0.39 0.02 inch) (13) Main bearing cap