809497A 1 Mercury VALVE GUIDE REAMER

Hot parts or hot components can cause burns or personal injury. Do not allow these parts to contact your skin. Let the engine cool down before performing maintenance on or around the engine.
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 4C-5894 Tap (M10 X 1)(1) 1
B 9U-7067 Tapered Cap/Plug(2) 1
C 264-4355 Nylon Brush(2) 1
D 266-2281 Nylon Brush(2) 1
E - Loctite C5-A® In North America
Loctite 8008® EAME alternative -
(1) Use the 4C-5894 Tap to chase the port threads if necessary.
(2) Along with a new cylinder pressure sensor, these parts are included in the 526-1451 .
Illustration 1 g06209600
(1) Cylinder pressure sensor
(2) Sensor harness assembly
(3) Area around the sensor
Clean area (3) around the sensor (1) before removing sensor harness (2) to avoid liquid or debris from getting into the harness connector or the sensor. Clean area with compressed air or vacuum.Note: Do not exceed 689 kPa (100 psi) of compressed air.
Inspect area (3) around the sensor (1) to ensure that the area is free of debris that could fall into the combustion chamber.
Remove sensor harness (2) from pressure sensor (1). Pull from the round connector. Do not pull on the wires. Do not twist the round connector.Note: If desired, use spark plug wire pliers or hose grip pliers to help with the connector removal.
Loosen pressure sensor (1) . Finish removing the pressure sensor by hand.Note: Do not use an impact wrench.
Insert Tooling (B) into the sensor port to prevent debris from falling into combustion chamber.Installation Procedure
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 2 g06209601
(3) Area around the sensor
(4) Port threads
(5) Port surface
(6) Sensor seat
Inspect area (3) around the sensor (1) to ensure that the area is free of debris that could fall into the combustion chamber.
If using previously removed cylinder heads, remove Tooling (B) from the sensor port.
Inspect port threads (4) to ensure that the threads are free of any debris.If cylinder heads were delivered with Tarp or Tarp-B applied, clean per the Engine News, SEBD9204, Uses, Characteristics, And Removal of Castrol Tarp®, Tarp-B®, And 4164® prior to installing on the engine. If the heads were delivered with a different rest preventer applied, clean appropriately prior to installing on the engine.Note: If the engine and DGB retrofit kit are going to be painted, ensure that all sensors, actuators, and wiring harnesses are installed and connected or ensure that any open holes or exposed connectors are fully masked. Paint in port threads will affect the sensor tightening torque. Paint inside connectors may prevent a good electrical connection.
Use Tooling (C) to clean port threads (4) and port surfaces (5) . Ensure any Tarp is removed from the cylinder pressure sensor threads.Note: Do not use metal brushes.Note: Any Tarp left in the threads will affect the tightening torque of the cylinder pressure sensor.
Use Tooling (D) to clean sensor seat (6).Ensure any Tarp is removed from the cylinder pressure sensor seat.Note: Do not use metal brushes.Note: Any Tarp left on the seat may cause premature sensor failure due to combustion gas leakage.
Inspect sensor seat (6) to ensure that the seat is free of debris. It is important for the sensor seat to be clean so the sensor seals to the cylinder head.Note: A poor seal at this location may cause premature sensor failure because of combustion gas leakage.
Use shop air to blow out the port in the cylinder head.
Illustration 3 g06209600
(1) Cylinder pressure sensor
(2) Sensor harness assembly
(3) Area around the sensor
Clean the threads of pressure sensor (1) with a nylon brush.Note: Do not use steel or brass brushes.
Inspect pressure sensor (1). Ensure all surfaces and the connector are free of debris, liquid, or damage.
Lightly apply Tooling (E) to pressure sensor threads.
Hand-tighten sensor into port until seated.Note: Use caution to keep the pressure sensor tip from contacting any hard surfaces during installation.Note: Do not use an impact wrench.
If sensor resists hand-tightening, use Tooling (A) to clean the port threads in the cylinder head. Contain metal debris using a small magnet and/or vacuum. Repeat steps 4 through 12.
Tighten sensor to a torque of 11.5 1 N m (102 9 lb in) .Note: Do not use flexible/universal wrenches or extensions when torquing the sensor.Note: Applying too much torque to the sensor may cause premature sensor failure.Note: There will be a gap between the sensor and the cylinder head when the sensor is fully seated.
Inspect the round connector of sensor harness (2) for liquid, debris, or damage. Clean or replace if necessary.
Connect sensor harness (2) to pressure sensor (1) by pushing the connector until an audible click is heard. Do not twist the round connector. A confirmation tug should be applied to verify that the connector is latched.