Mercury 35/40HP 2 Cylinder Outboards Service Manual PN 90-42794--1, Page 85Get this manual
Connecting Rod Cap Alignment Check each connecting rod cap for correct alignmentIf not aligned, ridge can be seen or felt at the separating line as shown belowCorrect any misalignmentSide View Correct Side View Incorrect
Place sleeve (a) which is part of piston pin tool (9176159A 1) into connecting rod and install needle bearings around sleeve as shown
End View Correct
End View Incorrect
Heat dome of piston using torch lamp to approximately 190 If you do not have tempermeter, heat piston for minutesNOTE: Use an asbestos glove to handle heated pistonPlace locating washers (a) on connecting rod Thread connecting rod screws (with Loctite Grade "An) finger-tight while checking for correct alignment of the rod cap as shownTighten connecting rod screws (using 14 in12 point socket) evenly in three progressive steps until torqued to 180 lbin (20 Nm) Carefully position piston over end of rod Make sure locating washers remain in place