Mercury 7U7Z-6049-BARH Cylinder Head Assembly

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Remove the cylinder head bolts following the reverse of the recommended tightening sequence, loosening them in 1/4-turn increments. These are torque-to-yield bolts and should be discarded.

It may be more practical and economical for the home mechanic to purchase replacement heads due to the specialized tools required for disassembly and inspection procedures, as well as the potential unavailability of replacement parts.

Pull up the slack chain and insert the camshaft sprocket, aligning it with the camshaft, but do not tighten the sprocket bolt at this time.

Caution 1: These engines are difficult to work on and require special tools for many procedures. For any procedure involving timing chains, camshafts, or cylinder head removal, the steps must be read carefully, and disassembly must proceed using the special tools; otherwise, damage to the engine could result. Caution 2: The engine must be completely cool when the cylinder heads are removed. Failure to allow the engine to cool off could result in cylinder head warpage. Caution 3: The manufacturer states that the cylinder head cannot be machined in the event of warping. If the cylinder head warpage exceeds 0.001 inch (0.0254 mm), it must be replaced.

Disconnect the coolant hose from the EGR unit and remove the hose from its bracket.

The mating surfaces of the cylinder head and block must be perfectly clean. Use a gasket scraper to remove all traces of carbon and old gasket material, then clean the mating surfaces with lacquer thinner or acetone.

Remove the exhaust manifolds.

If the height is greater than the figure, shims can be added under the springs to correct it.

Remove the drivebelt.

1. Compress the springs with a valve spring compressor. 2. Carefully install the keepers in the upper groove. 3. Slowly release the compressor and make sure the keepers seat properly. 4. Apply a small dab of grease to each keeper to hold it in place if necessary.

Check the rocker arm faces (the areas that contact the pushrod ends and valve stems) for pits, wear, galling, score marks, and rough spots.

Install a new head gasket on the cylinder block, ensuring the correct side faces up.

Do not pry the heads at the sealing surfaces.

Unbolt and remove the cylinder heads, prying them up at a point where the gasket surfaces won't be damaged. Caution: Do not pry the heads at the sealing surfaces.

Remove the valve cover.

9. Remove the alternator and the lower alternator mounting bracket. 10. Remove the upper radiator hose and the coolant bypass hose. 11. Disconnect the engine coolant temperature (ECT) sensor. 12. Remove the accessory bracket. 13. Remove the thermostat housing. 14. Remove the bolts that retain the engine wiring harness to the engine brackets.