883215 1 Mercury TUBE

Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) - Guide Bolt
(M8 by 60 mm) 2
A(2) - Guide Bolt
(M9 by 95 mm) 2
C - Straight Edge 1
(1) C0.5 and C0.7 engines
(2) C1.1, 3011C, and C1.6 engines
Thoroughly clean the gasket surfaces of the cylinder head and the cylinder block. Do not damage the gasket surfaces of the cylinder head or the cylinder block. Ensure that no debris enters the cylinder bores, the coolant passages, or the lubricant passages.
Inspect the gasket surface of the cylinder head for distortion. Refer to Specifications, "Cylinder Head" for more information. If the gasket surface of the cylinder head is distorted beyond maximum permitted limits, replace the cylinder head.
Illustration 1 g01317467
Typical example
Illustration 2 g01317471
Typical example
Illustration 3 g06221686
Typical example
Inspect dowels (3) for damage. If necessary, replace the dowels in the cylinder block.
Install Tooling (A) to the cylinder block. Refer to Illustration 1.
Ensure that the new cylinder head gasket (4) is the same thickness as the cylinder head gasket that was previously removed. The thickness of the cylinder head gasket is indicated by the number that is shown at Position (X). Refer to Specifications, "Cylinder Head" for more information.
Align cylinder head gasket (4) with Tooling (A) and with dowels (3). Install the cylinder head gasket onto the cylinder block.
Use a suitable lifting device to lift the cylinder head. The weight of the cylinder head is approximately 30 kg (66 lb).
Use Tooling (A) to align cylinder head (2) with the cylinder block. Install the cylinder head to the cylinder block.Note: Ensure that the cylinder head is correctly positioned onto dowels (3).
Remove Tooling (A).
Illustration 4 g06221620
Clean bolts (1). Follow Step 10.a through 10.b to inspect the bolts.
Check the length of bolts (1).
Use Tooling (C) to check the threads of bolts (1). Refer to Illustration 4. Replace any bolts that show visual reduction in the diameter of the thread over Length (Y).
Install bolts (1) to cylinder head (2).
Illustration 5 g01317344
The tightening sequence for a two cylinder engine
Illustration 6 g01317351
The tightening sequence for a three cylinder engine
Illustration 7 g01309552
The tightening sequence for a four cylinder engine
For C0.5 engines, tighten the bolts to a torque of 37 N m (27 lb ft). Use the numerical sequence that is shown in Illustration 5.For C0.7 cylinder engines, tighten the bolts to a torque of 37 N m (27 lb ft). Use the numerical sequence that is shown in Illustration 6.For C1.1/3011C, 403D-11 engines, tighten bolts (1) to a torque of 51 N m (38 lb ft). Use the numerical sequence that is shown in Illustration 6.For C1.6 engines, tighten bolts (1) to a torque of 51 N m (38 lb ft). Use the numerical sequence that is shown in Illustration 7.
If necessary, install the water temperature regulator to the cylinder head. Refer to Disassembly and Assembly, "Water Temperature Regulator- Remove and Install" for the correct procedure.End By:
Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install" for the correct procedure.
Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install" for the correct procedure.
Install the glow plugs. Refer to Disassembly and Assembly, "Glow Plugs - Remove and Install" for the correct procedure.
Install the fuel injectors. Refer to Disassembly and Assembly, "Fuel Injector - Install" for the correct procedure.
Install the fuel filter base. Refer to Disassembly and Assembly, "Fuel filter Base - Remove and Install" for the correct procedure.
Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install" for the correct procedure.