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SERVICE MANUAL Number 2 Sections 1 thru 10 Brunswick Corp. 1986 Printed in U.S.A. 90-71707 286 Section 1 - General Information 1A - General Information 1B - Tuneup 1C - Lubrication Section 2 - Removal/Installation/Alignment 2A - MerCruiser 120-140-165-470 2B - MerCruiser V-8 I-Drive Models 2C - MerCruiser II-TR and II-TRS Stern Drive 2D - General Installation Section 3 - Electrical System 3A - Starting System 3B - Ignition System 3C - Alternator System 3D - Instrumentation 3E - Wiring Diagrams Section 4 - Fuel System 4A - Fuel Pumps 4B - Carburetors Section 5 - Engine 5A - Engine Mechanical, In-Line 5B - Engine Mechanical, V-8 Ford 5C - Engine Mechanical, V-8 GM 5D - Engine Mechanical, 470 Model Section 6 - Drive Systems 6A - MerCruiser I Drive Unit 6B - MerCruiser II-TR Drive Unit 6C - MerCruiser II-TRS Drive Unit 6D - Direct Drive Transmission 6E - MerCruiser II-TR and II-TRS Transmission Section 7 - Accessories 7A - Power Trim System 7B - Steering Systems 7C - Remote Controls 7D - Cooling 7E - General Accessories Section 8 - Specifications 8A - Tune-Up and General 8B - Internal Engine 8C - Torqure Specs 8D - Propeller Chart Section 9 - 400 Jet Drive Section 10 - Troubleshooting MODELS COVERED IN THIS MANUAL MERCRUISER STERN DRIVE ENGINES (MCM) Model Serial Number MCM 120 3770650 - 4952700 MCM 140 3771645-4918569 MCM 165 3774865 - 4884834 MCM 470 4886619 and Below MCM 888 3777490 and Above MCM 898 4887829 and Below MCM 225 S (Ford) All MCM 225TR (Ford) 3779775 and Above MCM 228 4902304 and Below MCM 228TR All MCM 233 All MCM 250 (350 CID) 4768000 and Above MCM 255 (Ford) 3838788 and Above MCM 25 (GM) 4175500 and Above MCM 280 All MCM 330 4889679 and Below 400 Jet All TRANSOM ASSEMBLY AND STERN DRIVE UNITS Model Serial Number MC 120/140 3780850 - 4893634 MC 165 3780850 - 4890459 MC 470 4893834 and Below MC 888 3784375 and Above MC 225 S All MC 233 All MC 898/228 4898729 and Below MC 250 All MC TR 3787240 - 5009866 MC TRS 4895289 and Below MC Jet Drive All MERCRUISER INBOARD ENGINES (MIE) Model Serial Number MIE 198 All MIE 225 (Ford) 3750508 and Above MIE 228 4931099 and Below MIE 233 All MIE 255 (Ford) 3839488 and Above MIE 255 (G.M.) 4924564 and Below MIE 330 4890179 and Below MIE 350 All Notice to Users of This Manual This service manual has been written and published by the service department of Mercury Marine to aid our dealers' mechanics and company service personnel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures of these products, or like or similar products manufactured and marketed by Mercury Marine. That they have been trained in the recommended servicing procedures of these products which includes the use of mechanics common hand tools and the special Mercury Marine or recommended tools from other suppliers. We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the product's safety will be endangered by the service procedure selected. All information, illustrations and specifications contained in this manual are based on the latest product information available at time of publication. It should be kept in mind, while working on the product, that the electrical system and ignition system is capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material which could enter the cylinders and cause extensive internal damage when the engine is started. It is important to note that, during any maintenance procedure, replacement fasteners must have the same measurements and strength as those removed, whether metric or customary. (Numbers on the heads of the metric bolts and on surfaces of metric nuts indicate their strength. Customary bolts use radial lines for this purpose, while most customary nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfuction, or possibly personal injury. Therefore, fasteners removed should be saved for re-use in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. Replacement Parts WARNING Electrical, ignition and fuel system components on MerCruiser Engines and Stern Drives are designed and manufactured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire or explosion. Use of replacement electrical, ignition or fuel system components, which do not comply to these rules and regulations, could result in a fire or explosion hazard and should be avoided. When servicing the electrical, ignition and fuel systems, it is extremely important that all components are properly installed and tightened. If not, any electrical or ignition component opening would permit sparks to ignite fuel vapors from fuel system leaks, if they existed. Engine Mechanical Components Many of the engine mechanical components are designed for marine applications. Unlike automotive engines, marine engines are subjected to extended periods of heavy load and wide-open-throttle operation, therefore, require heavy-duty components. Special marine engine parts have design and manufacturing specifications which are required to provide long life and dependable performance. Marine engine parts also must be able to resist the corrosive action of salt or brackish water that will rust or corrode standard automotive parts within a short period of time. Failure to use recommended Quicksilver service replacement parts can result in poor engine performance and/or durabiltiy, rapid corrosion of parts subjected to salt water and possibly complete failure of the engine. Use of parts other than recommended service replacement parts will void the warranty on those parts which are damaged as a result of the use of other than recommended parts. GENERAL INFORMATION MERCRUISER Section 1 TABLE of CONTENTS Page How to Use This Manual 1A-1 Page Numbering 1A-1 Directional References 1A-2 Engine Rotation Terminology 1A-2 Engine Identification 1A-2 Engine Serial Number Location 1A-3 Stern Drive Serial Number Location 1A-4 Flushing Cooling System 1A-5 Winter Storage-Marine Engines 1A-6 Winter Storage of Batteries 1A-7 Returning Engine to Service 1A-7 Winter Storage-Stern Drive Units 1A-8 Power Trim Operation 1A-8 Pre-lgnition and Detonation 1A-10 Trim Tab 1A-10 MerCruiser Fuel System 1A-11 Propellers 1A-12 Tune-Up 1B_1 Description 1B-1 Compression Test 1B-1 SparkPlugs 1B-1 ignition System 1B-2 Carburetor Adjustment 1B-5 Throttle Cable Adjustments 1B-6 Fuel Pump Pressure Test 1B-6 Battery and Battery Cables 1B-7 Valve Adjustment 1B-7 Manifold 1B-7 Crankcase Ventilation 1B-7 Lubrication 1C-1 Lubricant and Maintenance Chart 1C-1 Stern Drive Lubricant Capacities 1C-2 Engine Lubrication Oil Selection 1C-3 Draining Engine Oil 1C-3 Filling Engine Crankcase 1C-3 Maintaining Oil Level 1C-3 Oil Filter 1C-4 Components 1C-4 Stern Drive Lubrication 1C-4 Checking Lubricant Level 1C-5 Draining and Filling Drive Unit 1C-6 Points of Lubrication 1C-7 SECTION 1 - GENERAL INFORMATION PART A - GENERAL INFORMATION A BRUNSWICK COMPANY INDEX Page Howto Use This Manual 1A-1 Page Numbering 1A-1 Directional References 1A-2 Engine Rotation Terminology 1A-2 Engine Identification 1A-2 Engine Serial Number Location 1A-3 120-140-165 1A-3 888 and 225-S 1A-3 233, 225 II-TR and 255 IL-TR and 255 H-TRS with Serial No. 4175499 and Below 1A-3 255 (Serial No. 4175500 and Above), 330, 350 and 400 Series Jet 1A-3 470 1A-3 898, 228, 228-TR, 250 (Serial No. 4657551 and Above), 280-TRS, 330-TR, 330-TRS 1A-4 Stern Drive Serial Number Location 1A-4 I-Driv e 1A-4 II-TR and II-TRS 1A-4 Flushing Cooling System 1A-5 MerCruisers with Water Pump Located in Drive Unit 1A-5 MerCruisers with Engine Driven Pickup Water Pump. 1A-5 Winter Storage- Marine Engines 1A-6 120-140-165 1 A-6 V-8 Models 1A-6 Winter Storage of Batteries 1A-7 Returning Engine to Service 1A-7 Winter Storage-Stern Drive Units 1A-8 I-Drive 1A-8 E-TR andH-TRS 1A-8 PowerTrim Operation 1A-8 Operating 3-Switch Control 1A-8 Operating 2-Switch Control 1A-9 Indicator Readjustment 1A-9 Pre-lgnition and Detonation 1A-10 Pre-lgnition 1A-10 Pre-lgnition Causes 1A-10 Detonation 1A-10 Other Causes of Detonation 1A-10 Trim Tab 1A-10 Removal and Replacement 1A-10 Trim Tab Adjustment 1A-11 MerCruiser Fuel System 1A-11 Fuel Tank-Cautions 1A-11 Fuel Lines-Length and Sizes 1A-11 Propellers 1A-12 How Does a Propeller Work? 1A-12 Rotation 1A-12 Propeller Diameter 1A-12 Propeller Pitch 1A-12 Propeller Slip 1A-12 Cavitation 1A-12 Cupped Propeller 1A-12 Two and Three-Blade Propellers 1A-13 Correct Propeller? 1A-13 MERCRUISER GENERAL INFORMATION 777 R MERCRUISER GENERAL INFORMATION 777 R GENERAL INFORMATION HOW to USE THIS MANUAL PAGE NUMBERING Two number groups appear at the bottom of each page. The example, below, is self explanatory. Example: This comprehensive overhaul and repair manual is designed for mechanics to use as a reference guide for MerCruiser engines and drive units with Serial No. 3750508 and above. The manual is divided into SECTIONS which represent major components and systems. Following are the SECTIONS which compose this manual: Section 1 2 3 4 5 6 7 8 9 10 SECTIONS are separated by dividers (heavier color paper) which enable the user to quickly locate any desired SECTION. A table of contents, which lists major subjects and page numbers, is printed on the reverse side of each SECTION divider. Section Headinq General Information Removal, Installation and Alignment Electrical Systems Fuel Systems Engine Drive Systems Accessories Specifications Tools Troubleshooting The SECTIONS are further divided into PARTS. Each PART has a colored title page which is the same color as the SECTION divider. An index for the particular PART is printed on the title page. NOTE: To find the subject in which you are interested, turn directly to the "Table of Contents"and "Index". EXAMPLE: To find pinion gear shim information in Mer- Cruiser 22511-TR gear housing, first turn to the "MerCruiser Service Manual Outline" (located in front of manual). Find the Section Number pertaining to the subject of interest, which would be "Section 6, Drive Systems". Then, Section 6, "Table of Contents" tells you that 225II-TR Drive is outlined in Part B. Finally, Part B "Index" is broken down in detail. Pinion gear shimming would be under: Page Gear Housing Reassembly Shimming (Pinion Gear) 6B-9 By using these guide sheets, you can quickly fiAd that MerCruiser 225II-TR pinion gear shimming is in Section 6 Part B - Page 9. 777R2 1A-1 DIRECTIONAL REFERENCES Front of boat is bow: rear is stem. Starboard side is right side; port side is left side. In this maintenancedirectional references are given as boat from stem, looking toward bow. (Figure 1) Figure 1. Directional Reference ENGINE ROTATION TERMINOLOGY Engine rotation is the direction (left-hand or right-hand) of clockwise) rotation. Inboard models may be either left or right hand rotation. rotation of the crankshaft, as observed from the transmission or drive unit end of the engine. Do not rely on propeller rotation, as it is not necessarily the All MerCruiser stern drive engines are left hand (counter-same as engine rotation. ENGINE IDENTIFICATION MODELS with "GM" ENGINE BLOCK MODELS with "FORD" ENGINE BLOCK manual, all they appear when viewing STARBOARD (RIGHT) FORE or BOW (FRONT) AFT or STERf (REAR) Model Serial No. 120 All 140 All 165 All 898 All 228 All 250 All 255 4175500 and Above 280 All 330 All 350 All 400-J et All Model Serial No. 888 All 225 All 225-S All 233 All 255 4175499 and Below MODELS with "MERCRUISER" BLOCKS Model Serial No. 470 All 1A-2 - MERCRUISER GENERAL INFORMATION 777 R2 ENGINE SERIAL NUMBER LOCATION IMPORTANT: Serial numbers are the manufacturer's key to numerous engineering details applicable to the engine. When ordering parts, accessories and tools, or when corresponding with the manufacturer or dealer in regard to service matters, always specify engine serial number. MERCRUISER 120-140-165 MERCRUISER INBOARD ENGINES 255 (Serial Serial number is located on rear right side of engine block No. 4175500 and Above), 330, 350 and 400 above starter motor. (Figure 2) SERIES JET ^Housing Circuir br*ok 2. Route shift cable in cable clamp (located on engine flywheel housing cover) and bend clamp shut. 3. Remove cotter pin from shift cutout lever recess and remove elastic stop nut and flat washer from shift lever adjustable stud. Place brass barrel of drive unit shift cable into recess of shift cutout lever and place cable end guide on shift lever stud. (Figure 3) 4. Insert cotter pin thru cutout switch lever and spread ends of pin. 5. Place flat washer on shift lever stud (located in slotted hole) and thread on elastic stop nut DO NOT tighten nut securely, as end guide must pivot freely on stud. (Figure 3) Figure 3. Installing Drive Unit Shift Cable INSTALLING and ADJUSTING REMOTE CONTROL SHIFT CABLE IMPORTANT: Remote control shift cable may be installed from right (starboard) or left (port) side of boat. If shift cable is installed from right side, cable brass barrel is installed on shift lever mounting stud. (Figure 4) If shift cable is installed from left side, cable brass barrel is installed on anchor stud (located on inner transom plate). Shift adjustments are the same. Following figures are of RIGHT HAND installation. NOTE: Before beginning shift adjustment, adjustable stud (Figure 3 - anchor point for drive unit shift cable) MUST BE to bottom of slot in shift lever. (Bottom of slot is toward reverse lock valve.) 1. Remove 2 elastic stop nuts and 2 flat washers from remote control shift cable anchor studs. DO NOT remove 2 of the washers from the shift plate anchor stud and DO NOT remove spacer from anchor stud on shift lever. NOTE: Lubricate cable attaching sleeves and studs with Multipurpose Lubricant (C-92-63250). 2. Shift drive unit into full forward by moving the shift lever to the right (when viewing lever from inside boat) as far as it will go. While shifting, tum propeller shaft counterclockwise until shaft stops, ensuring full clutch engagement. 3. Move remote control shift handle to full forward position. 4. Route remote control shift cable from right (starboard) side of engine. 5. Adjust and attach remote control shift cable as follows: a. Lightly pull brass barrel away from remote control shift cable end guide (to eliminate slack in cable). b. Adjust brass barrel on remote control shift cable to align brass barrel guide with anchor stud on shift lever and cable end guide with anchor stud on shift plate. c. After remote control shift cable has been aligned with anchor studs, back brass barrel off 4 turns (away from cable end guide). (Figure 4) d. Install shift cable on anchor studs and secure with flat washers and elastic stop nuts. (Figure 4) IMPORTANT: DO NOT tighten elastic stop nuts against cable, as end guide and brass barrel must pivot freely on anchor studs. 977R3 6. Move remote control shift handle to full reverse position while turning propeller shaft clockwise until shaft stops, ensuring full clutch engagement. 7. Check shift cutout switch lever position. (Figure 5) If lever is deflected from its neutral position (center of slot), adjust remote control cable brass barrel one turn at a time (4 turns MAXIMUM) toward end guide until shift cutout switch lever is positioned in center of switch actuating arm slot. Figure 4. Installing and Adjusting Remote Control Shift Cable IMPORTANT: If a standard MerControl (side mount) or extra long remote control cables are used, or if there are a large number of bends in remote control shift cable, an additional adjustment may be necessary. 8. Perform following check to determine if further shift adjustment is required. If adjustment is necessary, adjust as follows: a. Out of water, engine stopped - check and adjustment: Move remote control shift handle into reverse position until throttle BEGINS to open. Turn propeller shaft clockwise. Clutch should engage and cause propeller to lock. If clutch does not engage, loosen adjustable stud, which anchors drive unit shift cable to shift lever, and move it forward in shift lever slot until firm clutch engagement is obtained. Recheck shift cutout switch Figure 5. Checking and Adjusting Shift Cutout Switch Lever Location MERCRUISER REMOVAL-INSTALLATION-ALIGNMENT - 2A-1 lever. (Figure 5) Lever must be in neutral position c. With boat in water and engine running, operate drive (center of slot in switch actuating arm). Tighten unit in reverse gear. If drive unit trails out (will not adjustable anchor stud at necessary" location of shift hold in down position), over-adjust reverse lock valve lever slot. one mark at a time until drive unit holds. b. In the water, engine running - check and adjustment: With engine running, move remote control shift handle into reverse position. Reverse clutch should engage BEFORE throttle BEGINS to open. If throttle opens before reverse clutch engages, refer to "Out of water, engine stopped check and adjustment", preceding, and adjust shift cable. 9. Adjust reverse lock valve (if applicable) as follows: a. Move remote control shift handle to full reverse position while turning propeller shaft clockwise until shaft stops, ensuring full clutch engagement. b. Loosen 2 shift lever to reverse lock valve attaching nuts and move forward nut in direction required to line up raised triangular mark on cam with SECOND raised mark on reverse lock valve cover. (Figure 6) Tighten 2 shift lever attaching nuts. CAUTION: Drive unit may be locked in neutral if reverse lock valve is over-adjusted. RIDE-GUIDE STEERING INSTALLATION NOTE: Steering cable can be attached to drive unit from either right (Figure 1J or left (Figure 3) side. 1. Attach steering link rod thru hole located in end of steering lever On drive unit. Secure rod to lever with special sleeve, thin washer and castle nut. Torque nut to specification (DO NOT over-torque) and. if necessary, back nut off slightly to install cotter pin. 10146 Figure 1. Attaching Steering Cable to Drive Unit from Right Figure 2. Steering Link Rod Attached 2. Lubricate inside of cable guide tube with Multipurpose Lubricant (C-92-63250). 3. Insert cable end thru tube and thread coupler nut on tube and tighten securely. Figure 3. Attaching Steering Cable to Drive Unit from Left Locking — Cotter Pin Figure 4. Locking Sleeve installed on Coupler Nut 4. Install steering cable coupler nut locking device (Figure 4) as follows: a. Position rubber bumper into locking sleeve, inserting bumper locating pin into hole provided (if not already installed). 977R3 MERCRUISER REMOVAL-INSTALLATION-ALIGNMENT - 2A-1 b. Position locking sleeve over steering cable at cable and B-32-78896) MUST BE installed before installing lock- coupler nut end. Slide locking sleeve over coupler nut, ing sleeve. as shown in Figure 4. Secure locking sleeve with cotter 5. Attach steering link rod to cable end, using thick washer as pin. Pin must be located between grease fitting and shown in Figure 2. Torque castle nut to 20-25 in. lbs. cable coupler nut. Spread ends of cotter pin. (23-29kg-cm) and, if necessary, back off nut slightly to install cotter pin. 6. Steering tube is pre-set and torqued at the factory. If ad- NOTE: When installing locking sleeve on Power Steering justment is necessary, see "Adjusting Steering (Rideequipped in-line engines, interference with hydraulic lines Guide)", following, after engine and drive unit are in- may exist. In this case, longer hydraulic lines (B-32-78895 stalled. ADJUSTING STEERING (RIDE-GUIDE) 1. Turn steering wheel to full left and right. Drive unit should Guide)", preceding.] traverse fully in both directions. If unit turns further in 2. Turn steering wheel until drive unit is centered. If, at this one direction than other, loosen adjusting nuts and move point, steering wheel is not centered correctly, adjust cable cable guide tube left or right to allow full traverse. Torque guide tube slightly either way to center steering wheel. adjusting nuts to 35-to-40 ft. lbs. (4.84-to-5.53mkg). Recheck Item 1, immediately preceding, after making the [Figures 1 and 3 under "Steering Installation (Ride-adjustment. TRIM SENDER INSTALLATION 1. Install hydraulic trim sender (if applicable) to transom bracket and transom and 2 lockwashers and lag screws. with two 9/32" (7.14mm) spacers between trim sender 2. Insert hydraulic trim sender lines as shown in Figure 5. INSTALLING H YDRAULIC HOSES 1. Remove cap from fitting (located on end of black 2. Immediately connect hose to pump. hydraulic hose) and remove threaded plug from pump. 3. Remove cap from fitting (located on end of gray reverse (Figure 5) lock valve hydraulic hose) and remove threaded plug from valve. (Figure 5) DO NOT allow oil to run out of hose and pump. Tighten fittings securely. 4. Clamp hydraulic hoses securely to transom plate at location shown in Figure 5. IMPORTANT: Failure to comply with preceding Steps 1, 2, 3 and 4 may cause hydraulic hose to become damaged and render hydraulic system inoperative. 5. Loosen pump reservoir vent screw. (Figure 5) Vent must be open for proper operation. 6. With unit down all the way in normal operating position, check oil level by removing "Fill" screw. If necessary, fill to bottom of threads with an SAE 5W-20 or SAE 5W-30 specification "SE" automotive oil. Do not overfill. 7. Replace "Fill" screw. ! 977R3 MERCRUISER REMOVAL-INSTALLATION-ALIGNMENT - 2A-1 SECTION 2 - REMOVAL, INSTALLATION and ALIGNMENT PART B - V-8 I-DRIVE MODELS A BRUNSWICK COMPANY INDEX Page MerCruiser V-8 I-Drive Engine 2B-1 Removal 2B-1 Installation and Alignment 2B-1 Throttle Cable Installation 2B-2 Stern Drive Unit 2B-3 Removal 2B-3 Installation 2B-3 Installing Trim Cylinders 2B-4 Propeller Installation 2B-5 Transom Plate Assembly 2B-6 Removal 2B-6 Installation 2B-6 Hydraulic Hose Connection 2B-7 Attaching Stern Drive Unit Shift Cable 2B-8 Installation Dimensions 2B-8 Attaching and Adjusting Remote Control Shift Cable 2B-9 Ride-Guide Steering Installation 2B-11 Adjusting Ride-Guide Steering 2B-11 MERCRUISER V-8 I-DRIVE ENGINE Removal NOTE: Stern drive must be removed prior to engine removal. Refer to "Stern Drive Removal" (use "Index"). 1. Disconnect battery cables from battery and remove instrument panel harness connector plug from engine harness receptacle. 2. Disconnect fuel line and throttle cable. 3. Remove shift cables (drive unit and remote control) from shift plate, then remove cables from "J " clamp (located on exhaust manifold). 4. Disconnect reverse lock switch wires from trim pump and trim pump red and black wires from engine or battery. 5. Disconnect water inlet hose and exhaust elbow bellows. 6. Remove gray "down" hose from reverse lock and black plastic hose from trim sender. Cap hoses and plug hose connections. 7. Disconnect any accessories that are connected to engine. 8. Support engine with suitable sling thru lifting eyes on engine and remove front and rear engine mounting bolts. 9. Carefully remove engine. Installation and Alignment NOTE: The transom plates and exhaust elbows must be installed before proceeding with "Engine Installation and Alignment". Refer to "Stern Drive Installation". 1. Place one double-wound lockwasher and one fiber washer on top of each inner transom plate engine support. (Fig. 1) Figure 1. Washers Positioned on Transom Plate Engine Supports 2. Lift engine with an overhead hoist, using a suitable sling and lifting eyes on engine. Engine must be suspended so that rear end is slightly lower than front, and front mounts are level. Figure 2. Exhaust Bellows Installed 977R3 Figure 3. Alignment Shaft Installed 3. Lower engine into position over transom plate and, while lowering, connect exhaust bellows to exhaust elbows. Allow rear engine mounts to rest on transom plate engine supports. Do not relieve hoist tension. 4. Place one steel washer and one spacer on each rear mount bolt and insert bolts down thru engine mounts, washers and mounting brackets. Thread elastic stop nuts on bolts and tighten to specification. (Figure 2) 5. Tighten exhaust bellows clamps securely. (Figure 2) 6. Insert end of Alignment Tool (C-91-57797A3) shaft (end without threaded hole) thru gimbal bearing. (Figure 3) Move gimbal bearing with shaft to align shaft with coupling spline and raise or lower front of engine with hoist to allow shaft to enter spline (and bottom out) freely. NOTE: If engine mount bases contact stringers when lowering front of engine, loosen locking nut "A "and turn mount adjusting nut "B" (Figure 4) counterclockwise to raise mounts up, away from stringers. Preliminary alignment must be made with front of engine supported evenly with hoist and mount bases not contacting stringers. 7. After preliminary alignment has been attained, remove alignment shaft and turn adjusting nuts ("B " on both front MERCRUISER REMOVAL-INSTALLATION-ALIGNMENT - 2A-1 mounts) clockwise to lower mounts (Figure 4) until mount 8. Relieve hoist tension entirely and fasten front mounts contacts top of stringers. At this point, stop turning nuts (with slotted mounting hole toward front of engine) to and place a reference mark on each adjusting nut "B". engine stringers. Use 3/8" (9.5mm) diameter lag bolts of Turn each nut clockwise one more full turn. sufficient length. 9. Recheck alignment shaft fit. Shaft must enter engii coupling freely. If not, turn both front mount adjusting nuts "B " an equal amount by alternating from one side to the other until shaft enters coupling spline (and bottoms out) freely. 10. Place hose clamp on water inlet hose and connect hose to water inlet tube. Tighten hose clamp securely. (Figure 5) Figure 4. Front Engine Mount Adjustments NOTE: Top surface of stringers must be located so that a minimum of 54" (6.35mm) up-or-down adjustment remains when mount bases are resting on stringers. 77lis is required to perform final engine alignment and re-alignment after boat has been in service. Throttle Cable Installation 1. Place remote control in neutral gear, idle position. 2. Remove nut and thin washer from bolt which passes thru carburetor throttle lever. NOTE: Leave spacer and bushing on bolt. 3. Place cable end guide over bushing. Place flat washer on bolt and tighten nut securely. (Figure 6) 4. Grasp throttle cable at point behind brass barrel and push toward throttle lever. Adjust brass barrel toanchor stud. Fasten barrel to stud with flat washer and nut. Tighten nut securely. Figure 6. Throttle Cable Installed align with 977R3 MERCRUISER REMOVAL-INSTALLATION-ALIGNMENT - 2A STERN DRIVE UNIT Removal 1. Shift drive unit into full forward. 4. Carefully remove drive unit. 2. Disconnect rear end of trim cylinders from drive unit. 5. Remove and discard drive shaft housing to bell housing 3. Support drive unit with suitable sling thru lifting eye on gasket. top cover and remove 6 nuts which hold drive unit to bell housing. Installation of Stern Drive Unit CAUTION: Check Engine Alignment with Engine Coupler Alignment Shaft (C-91-48247 or C-91-57797A3) before Installing Stern Drive Unit. (Refer to "Engine Installation and Alignment".) 1. Lubricate shifting slide assembly (Figure 1) with Multi-5. Drive unit must be in forward gear position. Lubricate purpose Lubricant (C-92-63250). coupler surface with Perfect Seal (C-92-34227). NOTE: Slide assembly is free to rotate on core wire, so be sure that slide is located in the upright position during NOTE: Since the fit between the universal joint yoke "0" installation. rings and gimbal housing ball bearing is tight, it is recommended that a coating of Multipurpose Lubricant be CAUTION: Be sure that rubber gasket is in place, or placed on the 2 "0" rings. This will facilitate installation water will leak into bellows. (Figure 1) of the universal joint yoke into the gimbal housing ball bearing. 6. Place drive shaft housing gasket on bell housing. (Figure 2) Figure 1. Lubricating Shifting Slide Assembly 2. Lubricate drive shaft housing pilot (Figure 2) with Multipurpose Lubricant (C-92-63250), and U-joint splines with Universal Joint Lubricant (C-92-74058). CAUTION: If locating slot of shift lever in bell housing and coupler of intermediate shift shaft In drive shaft housing are not aligned as described in Steps 3 and4, following, bell housing and shift shaft couplers will be damaged when drive unit is installed. 3. Align locating slot of shift lever coupler in bell housing straight to rear by moving shift lever to the right (facing transom from inside boat) and lubricate slot with Anti- Corrosion Grease (C-92-74048). 4. Align coupler of intermediate shift shaft in drive shaft housing for straight entry into locating slot of shift lever in gimbal housing. NOTE: It may be necessary to rotate propeller shaft to align intermediate shift shaft coupling with upper shift shaft slot. Figure 2. Lubricating Drive Shaft Housing Pilot 7. Insert stem drive unit into drive shaft housing bell bore as follows: (Figure 2) a. Guide universal joint shaft thru bearing in gimbal housing into drive coupling on engine. Also guide shift slide into opening in drive shaft housing. b. Be careful not to move shift slide assembly or shift shaft coupler. Shift shafts will not align if out of position. If universal joint shaft splines do not align with engine coupling splines, rotate propeller shaft counterclockwise until drive unit can be pushed into position. Propeller should be placed on shaft for easier rotation. DO NOT rotate propeller shaft clockwise, or drive unit shift shaft will turn out of forward position. 9. Fasten drive shaft housing to bell housing studs with 6 flat washers and elastic stop nuts. Tighten evenly to specification. (Figure 3) 977 R 2 MERCRUISER REMOVAL-INSTALLATION-ALIGNMENT - 2B-11 04604 Figure 3. Fastening Drive Shaft Housing to Bell INSTALLING TRIM CYLINDERS IMPORTANT: On trim cylinders with aluminum rod aft end (WITHOUT nylon coating), be sure that one small spiral grounding spring is installed between rubber bushings on each side of both forward and aft anchor pins. (Figure 4) They are necessary to ground the trim cylinders to the stern drive unit in order to reduce galvanic corrosion. NOTE: Forward anchor pin is installed previously. Refer to "Transom Plate Installation" (see "Index"). 1. Insert aft anchor pin thru hole in drive shaft housing and place one large washer, one rubber bushing and one spiral spring (if applicable) on aft anchor pin on each side of drive shaft housing. (Figure 4) 2. Loosen nuts, which retain hydraulic cvlinders to forward anchor pin, and place cylinders in position on aft anchor pin. 3. Place one rubber bushing in aft end mounting of each cylinder. Small diameter end of bushings face drive shaft housing. 4. Place one flat washer on each end of both cylinders next to rubber bushings. Thread nuts on anchor pins. Tighten 01531 nuts on FORWARD AND AFT anchor pins securely. Figure 4. Aft Anchor Pin Installed (Figure 5) Figure 5. Power Trim Cylinder Installed 977 R 2 MERCRUISER REMOVAL-INSTALLATION-ALIGNMENT - 2B PROPELLER INSTALLATION 1. Apply a liberal coat of Perfect Seal (C-92-34227) on splines of propeller shaft, especially if operated in salt water, to aid in removing at any future time. 2. Place thrust hub and washer assembly into propeller hub (shoulder into recess of propeller). 3. While aligning splines, place jet-prop propeller (with thrust hub assembly) and spline washer on propeller shaft in this order. (Figure 6) 4. Place propeller nut in groove of tab washer, thread propeller nut on propeller shaft and torque to specification. 5. Bend 3 of the tabs of tab washer down in grooves of spline washer to secure propeller nut. <------ Figure 6. Installing and Removing Propeller 977 R 2 MERCRUISER REMOVAL-INSTALLATION-ALIGNMENT - 2B- 11 TRANSOM PLATE ASSEMBLY REMOVAL NOTE: Drive unit and engine must be removed prior to transom plate assembly removal. Refer to "Drive Unit Removal"and "Engine Removal" (use "Index"). 1. Remove steering link rod. (Figure 1) 2. Disconnect and remove steering cable from tube. 3. Remove both hydraulic hoses from trim pump. Cap hoses and plug hose connections. 4. Remove exhaust separator (with exhaust elbows and exhaust bellows attached) from gimbal housing. 5. Disconnect tilt limit switch from trim wiring harness. 6. Remove screws and nuts, which hold inner and outer transom plates together, then remove inner transom plate and outer transom plate in that order. TRANSOM PLATE INSTALLATION 1. If hydraulic trim cylinders are not installed, install them per instructions following: a. Insert forward anchor pin in gimbal ring. b. Place one flat washer, one rubber bushing and one spiral spring on each side of forward anchor pin. c. Place cylinders in position on forward anchor pin. d. Place one rubber bushing, one flat washer and one nut on each end of forward anchor pin. Tighten nuts securely. 2. Set gimbal housing assembly and inner transom plate in position over openings in transom as follows: a. Insert shift cable, trim limit switch lead and hydraulic hose thru opening in transom and place gimbal housing in position. CAUTION: If gimbal housing is held in position by the trim limit switch leads while fastening inner transom plate, switch lead or switch could be damaged. b. While holding gimbal housing in this position, insert shift cable and hydraulic hoses thru large opening on inner transom plate and insert trim limit switch leads thru center hole of 3 small holes in inner transom plate, then set plate in position. (Figure 2) 3. Fasten gimbal housing assembly and inner transom plate to transom as follows: a. Thread 2 short cap screws with lockwashers thru top 2 holes of inner transom plate into gimbal housing. (Figure 2) Figure 2. Inner Transom Plate Positioned on Transom b. Insert 2 special anode head bolt assemblies with rubber plate into gimbal housing. Square washers should be seals placed between bolts and gimbal housing thru against transom plate. bottom 2 holes of gimbal housing, transom and inner 4. Tighten transom plate cap screws and elastic stop nuts transom plate. EVENLY, then torque to specification. Start by torquing c. Place flat washers on bolts and thread on 2 elastic stop from the center up, then center down. Retorque after a nuts. few minutes. d. Place flat washers on 2 studs, which protrude thru 5. Mount hydraulic trim sender assembly on transom plate inner transom plate, and thread on 2 elastic stop nuts. (Figure 2) with 2 cap screws and lockwashers and tighter securely. CAUTION: DO NOT attempt to drive cap screws thru 6. Install exhaust separator (with exhaust elbows and exhaust transom, as threads in gimbal housing will be damaged. bellows attached) to simbal housing, following: a. Be certain that mating surfaces on exhaust separator e. Thread 2 long cap screws with square flat washers and and gimbal housing are clean and that "0 " rings are lockwashers thru remaining holes in inner transom properly seated in grooves. (Figure 3) 977 R 2 MERCRUISER REMOVAL-INSTALLATION-ALIGNMENT - 2B-11 06704 Figure 3. Gimbal Housing "O" Ring Locations b. Place 4 hex head cap screws and one alien head cap screw with lockwashers thru separator into gimbal housing. (Figure 4) Torque screws EVENLY to specification. HYDRAULIC 1. Route hydraulic hoses toward pump as shown in Figure 5. 2. Remove cap from hydraulic fitting (located on end of black, gimbal housing hydraulic hose), remove threaded plug from hydraulic pump control valve and immediately connect hose to control valve. (Figures 5 and 6) 3. Connect black "down " hydraulic hose from pump control valve to trim sender (Figure 5) after removing plug from sender and cap from hose. NOTE: The gray "down" hydraulic hose and hose to trim sender are connected after engine is installed. 4. Connect gray "down" hydraulic hose from gimbal housing CAUTION: Be sure that "O" rings remain seated in grooves of gimbal housing to properly seal joint, or leakage will occur. HOSE CONNECTION to reverse lock valve after removing cap from hose fitting and plug from valve. (Figure 7) 5. Connect hydraulic hose from reverse lock valve (mounted on shift bracket) to shaft end of trim sender after removing cap from hose and plug from sender. (Figure 7) 6. Loosen pump reservoir vent screw. (Figure 6) Note that vent must be open for proper operation. 7. With drive unit down all the way in normal operating position, check oil level by removing "Fill" screw. (Figure 6) If necessary, fill to bottom of threads with an SAE 5W-20 or SAE 5W-30 specification SE automotive oil. DO NOT overfill. 8. Replace "Fill" screw. Figure 5. Routing Hydraulic Hoses 977R1 MERCRUISER REMOVAL-INSTALLATION-ALIGNMENT - 2B-7 "Down" Hydraulic Hose . Trim Sender "Down" Hydraulic Hose . Trim Sender Figure 6. Hydraulic Pump Mounted to Floor of Boat Figure 7. Hydraulic Hoses Connected to Trim Sender and Reverse Lock Valve ATTACHING STERN DRIVE UNIT SHIFT CABLE NOTE: DO NOT close "J" clip around shift cable. Clip will be bent closed after attaching and adjusting remote control shift cables. 3. Insert cotter pin thru cutout switch lever and spread ends of pin. (Figure 2) 4. Place flat washer on shift lever stud and thread on elastic stop nut. DO NOT tighten nut securely, as end guide mu: pivot freely on stud. (Figure 2) 1. Coat recess of cutout switch lever and shift cable anchor points with Multipurpose Lubricant (C-92-63250). (Figure 1) 2. Route shift cable under right (starboard) exhaust elbow and thru "J" clip. Place brass barrel of drive unit shift cable into shift cutout lever recess and place cable end guide on shift lever stud. (Figure 2) IMPORTANT: Brass barrel on drive unit shift cable is preset at factory and should not be threaded either way. INSTALLATION DIMENSIONS Figure 2. Drive Unit Shift Cable Fastened to Shift Lever and in Forward Gear IMPORTANT: Because of differences in shifting mechanisms, DO NOT use this new "Installation Dimensions" procedure for earlier MerCruiser Stem Drive Units. WARNING: On power package equipped with Quicksilver vacuum-operated Power Shift unit, engine must be running while adjusting shift cables. As a safety precaution, remove propeller if boat is NOT in water. 977 R 2 MERCRUISER REMOVAL-INSTALLATION-ALIGNMENT To obtain maximum adjustability on remote control shift cable, check the following dimensions on drive unit shift cable: 1. With cable end guide removed, shift unit in full forward gear. While shifting, turn propeller shaft counterclockwise until shaft stops, to assure full clutch engagement. Inner core wire of drive unit shift cable must extend exactly 1-3/8" (3.5cm) from end of cable guide insert. (Figure 3) 2B- 11 Figure 3. Support Tube and Core Wire Dimensions Slide support lube over core wire so that 'A" (12.7mm) of core wire is shown. (Figure 3) It is secured to core wire by crimping. 2. Slide cable end guide over end of cable thru cable anchor. 3. Snug one anchor screw and tighten the other to secure core wire. (Figure 3) 4. With cable end guide installed, shift unit in full forward gear. While shifting, turn propeller shaft counterclockwise until shaft stops, to assure full clutch engagement. Distance from centerline of brass barrel to centerline of cable end guide mounting hole must be exactly 6" (15cm). (Figure 4) Readjust brass barrel to achieve this dimension. NOTE: Brass barrel of drive unit shift cable fits into recess of shift cutout switch lever and is secured with a cotter pin. Brasi 6" (15cm) » IBarrel DOI I CI S Figure 4. Centerline to Centerline 6" (15cm) ATTACHING and ADJUSTING REMOTE CONTROL SHIFT CABLE IMPORTANT: Because of differences in shifting mechanisms, DO NOT use this new attaching and adjusting procedure for earlier MerCruiser 120-140-165 Stern Drive Units. IMPORTANT: Remote control shift cable MUST be installed as outlined, following, for either right (starboard) side or left (port) side installation of remote control. Before beginning shift adjustment, adjustable stud (Figure 1 - anchor point for drive unit shift cable) MUST be to rear of slot in shift lever. i. Shift drive unit into full forward by moving the shift lever (Figure 2) to the right (starboard) side of the boat as far as it will go. While shifting, turn propeller shaft counterclockwise until shaft stops, ensuring full clutch engagement. 2. Move remote control shift handle to full forward position. 3. Route remote control shift cable under right (starboard) exhaust elbow and thru "J" clip. Bend "J" clip closed around shift cables. Cables MUST be free to move back-and-forth thru "J1'clip. 977 R 2 4. Adjust and attach remote control shift cable as follows: a. Lightly pull brass barrel away from remote control shift cable end guide (to eliminate slack in cable). (Figure 5) b. Adjust the brass barrel on remote control shift cable to align cable end guide with anchor stud on shift lever and brass barrel with anchor stud on shift plate. (Figure 5) After remote control shift cable has been aligned with anchor studs, back brass barrel off 4 turns (away from cable end guide). (Figure 5) 08223 Figure 6. Shift Cables Attached and in Forward Gear d. Install shift cable on anchor studs and secure with flat washers and elastic stop nuts. Brass barrel must be installed over spacer on anchor stud. (Figure 6) IMPORTANT: DO NOT tighten elastic stop nuts against cable, as end guide and brass barrel must pivot freely on anchor studs. (Figure 6) 5. Move remote control shift handle to full reverse position while turning propeller shaft clockwise until shaft stops, ensuring full clutch engagement. 7. Check shift cutout switch lever roller position. (Figure 7) If lever is deflected from its neutral position (roller not in center of notch), adjust remote control cable brass barrel one turn at a time (4 turns MAXIMUM) toward end guide until shift cutout switch lever roller is positioned in center of switch actuating arm notch. MERCRUISER REMOVAL-INSTALLATION-ALIGNMENT - 2B- 11 Figure 7. Checking and Adjusting Shift Cutout Switch Lever Location IMPORTANT: If a standard MerControl (side mount) or extra long remote control cables are used, or if there are a large number of bends in remote control shift cable, an additional adjustment may be necessary. 8. Perform following check to determine if further shift adjustment is required. If adjustment is necessary, adjust as follows: a Out of water, engine stopped - check and adjustment: Move remote control shift handle into reverse position until throttle BEGINS to open. Turn propeller shaft clockwise. The clutch should engage and cause propeller to lock. If clutch does not engage, loosen adjustable stud, which anchors drive unit shift cable to shift lever, and move it forward in shift lever slot until firm clutch engagement is obtained. Recheck shift cutout switch lever roller. (Figure 7) Roller must be in neutral position (center of notch in switch actuating arm). Tighten adjustable anchor stud at necessary location of shift lever slot, b. In the water, engine running - check and adjustment: With engine running, move remote control shift handle into reverse position. Reverse clutch should engage BEFORE throttle BEGINS to open. If throttle opens before reverse clutch engages, refer to "Out of water, engine stopped - check and adjustment", preceding, and adjust shift cable. 9. Adjust reverse lock valve as follows: a. Move remote control shift handle to full reverse position while turning propeller shaft clockwise until shaft stops, ensuring full clutch engagement. Figure 8. Adjusting Reverse Lock Valve b. Loosen 2 shift lever to reverse lock valve attaching nuts and move forward nut in direction required to line up raised triangular mark on cam with SECOND raised mark on reverse lock valve cover. (Figure 8) Tighten 2 shift lever attaching nuts. CAUTION: Drive unit may be locked in neutral if reverse lock valve is adjusted too far. c. With boat in water and engine running, operate drive unit in reverse gear. If drive unit trails out (will not hold in down position), over-adjust reverse lock valve one mark at a time until drive unit holds. 977 R 2 MERCRUISER REMOVAL-INSTALLATION-ALIGNMENT - 2B-11 RIDE-GUIDE STEERING INSTALLATION Figure 9. Attaching Steering Cable to Transom Plate from Right NOTE: Steering cable can be attached to drive unit from either right (Figure 9) or left (Figure 10) side. 1. Connect steering link rod to steering lever with pivot bolt thru rod and nylon washer and wave washer between rod and lever. (Figure 11) Align wave washer with shoulder on pivot bolt and secure with flat washer and castle nut. Torque castle nut to specification and install cotter pin. If hole in link rod does not align with nearest notch in castle nut, back nut off slightly until it aligns and install cotter pin. Figure 10. Attaching Steering Cable to Transom Plate from Left 2. Lubricate inside of cable guide tube with Multipurpose Lubricant (C-92-63250). 3. Insert cable end thru guide tube and thread coupler nut on tube and tighten securely. (Figure 9 or 10) 4. Install locking sleeve on coupler nut and secure with cotter pin. (Figure 13) 5. Attach steering link rod to cable end with flat washer and castle nut. (Figure 12) Torque castle nut to specification, back off nut '/»-turn and install cotter pin. 6. If it is necessary to adjust steering after engine and drive unit are installed, see "Adjusting Ride-Guide Steering" (following). Figure 11. Connecting Steering Link Rod to Steering Lever Figure 12. Connecting Steering Link Rod to Cable End Figure 13. Locking Sleeve Installed on Coupler Nut ADJUSTING RIDE-GUIDE STEERING Turn steering wheel to full left and right. Drive unit should guide tube left or right to allow full traverse. Torque adjusting traverse fully in both directions. If unit turns further in one nuts to 35 to 40 ft. lbs. (4.84 to 5.53mkg). (Figures 9 and 10) direction than other, loosen adjusting nuts and move cable 977 R 2 MERCRUISER REMOVAL-INSTALLATION-ALIGNMENT - 2B- 11 SECTION 2- REMOVAL, INSTALLATION and ALIGNMENT PART C - II -TR and II -TRS STERN DRIVE A BRUNSWICK COMPANY INDEX Page MerCruiser II-TR and H-TRS Engine 2C-1 Removal 2C-1 Installation and Alignment 2C-1 Throttle Cable Installation 2C-3 Power Trim Hose Connections 2C-4 Shift Control Wiring Connections 2C-4 Stern Drive Unit 2C-5 Removal 2C-5 Installation 2C-5 Installing Trim Cylinders 2C-6 Propeller Installation 2C-6 Transom Plate Assembly 2C-7 Removal 2C-7 Installation 2C-8 Installing Hydraulic Pump Hoses 2C-8 Ride-Guide Steering Link Rod Installation .........................2C-9 Mounting Steering Unit to Transom Plate 2C-9 Connecting Hydraulic Hoses to Power Steering Unit and Filling System with Fluid 2C-10 Valve Balancing 2C-10 MERCRUISER II-TR and II-TRS ENGINE REMOVAL IMPORTANT: Stern drive unit must be removed prior to engine removal. Refer to "Stern Drive Removal" (use "Index"). 1. Loosen 6 transmission output housing rear mount bolts. (Figure 1) 2. Disconnect battery cables from battery and remove instrument harness connector plug from engine harness receptacle. 3. Disconnect fuel line and throttle cables from engine. 4. Remove electric shift wiring harness from terminal block (located on transmission). 5. Remove trim pump wires from engine. 6. Disconnect Power Steering hoses from steering valve assembly (on engines so equipped) and remove Power Trim hoses from reverse lock. Cap hydraulic hoses and plug their connecting passages. 7. Disconnect water inlet hose and exhaust elbows. 8. Remove vacuum hose from intake manifold. 9. Disconnect any accessories that are connected to engine. CAUTION: DO NOT lift engine until rear mount is disengaged from gimbal housing, as explained in Steps lOand 11. 10. Support engine with a suitable sling thru lifting eyes on engine and remove engine front mounting bolts. 11. Pull engine forward to disengage rear engine mount from gimbal housing and carefully remove engine. Figure 1. Transmission Output Housing Rear Mount Nuts ENGINE INSTALLATION and ALIGNMENT IMPORTANT: Prior to installing engine, transom plates must be installed as outlined in "Stern Drive Installation". Figure 2. Transmission Output Housing and Rubber Mount 1. Coat rubber rear mount (Figure 2) and gimbal housing opening (Figure 3) with Multipurpose Lubricant (C-92-63250). 2. Lilt engine with an overhead hoist, using a suitable sling and lifting eyes on engine. 977 R 2 IMPORTANT: Make sure that 6 nuts on transmission output housing are loose before installing. (Figure 2) 3. Position engine ahead of inner transom plate so that transmission output housing (Figure 2) is in line with large opening in inner transom plate. (Figure 3) 07497A Figure 3. Inner Transom Plate Opening 4. Move engine toward inner transom plate and. at the same time, guide transmission output housing into gimbal housing opening until output housing bottoms-out on shoulder in gimbal housing. Be careful that transmission output housing and rubber mount do not become damaged. CAUTION: Transmission output housing MUST BOTTOM-OUT on SHOULDER in gimbal housing or exhaust elbow misalignment will result, with subsequent damage to exhaust system. MERCRUISER REMOVAL-INSTALLATION-ALIGNMENT - 2B- 11 5. Relieve hoist tension, as required, to allow transmission output housing to seat in gimbal housing. IMPORTANT: Do not relieve hoist tension entirely at this time, as transmission and output housing may be damaged. 6. Position alignment tool plate on shaft, as shown in Figure 4. Thread Extension (C-91-66695A1) onto Alignment Shaft (C-91-57797A3), insert end of alignment tool into opening in bell housing and into transmission output housing. (Figure 4) Insert shaft until it bottoms-out in transmission output housing. Figure 4. Alignment Tool Location 7. Slide plate toward bell housing. Raise or lower front of engine with hoist to allow shoulder on plate to enter bell housing opening. (Figure 5) 07488 Figure 5. Tool Plate Installed 8. With alignment tool plate positioned in bell housing and engine supported with hoist, front engine mount supports should be constructed so that mounts will rest on top of supports without disturbing alignment tool plate position when hoist tension is relieved. IMPORTANT: Engine alignment should be near to correct before front engine mounts are fastened to engine bed. Only small adjustment should be necessary in following procedure. 9. Relieve hoist tension entirely and fasten front mounts (with slotted mounting hole toward front of engine) to engine bed. Use 3/8" (9.5mm) diameter lag bolts of sufficient length. CAUTION: Steering link rod must be disconnected before proceeding with engine alignment. 10. Push alignment shaft and plate toward engine and, while holding plate against bell housing, check for gap between plate and rear surface of bell housing at 12, 3, 6 and 9 o'clock positions. Engine alignment is correct when there is no gap at any point. If gap exists, proceed as follows: GAP AT 12 O'CLOCK POSITION Raise front of engine. Loosen locking nuts "A " (Figure 6) and turn adjusting nuts "B " counterclockwise. Turn adjusting nuts "B" (on both front mounts) an equal amount by alternating from one side to the other until gap no longer exists. Retighten nuts "A " securely. GAP AT 6 O'CLOCK POSITION Lower front of engine. Loosen locking nuts "A " (Figure 6) and turn adjusting nuts "B " clockwise. Turn adjusting nuts "B " (on both front mounts) an equal amount by alternating from one side to the other until gap no longer exists. Retighten nuts "A " securely. GAP AT 3 O'CLOCK POSITION Loosen lag screws which attach mounts to engine bed. Move engine to the right (starboard), using adjustment slot (Figure 6), until gap no longer exists. Retighten engine mount to engine bed lag screws securely. GAP AT 9 O'CLOCK POSITION Loosen lag screws which attach mounts to engine bed. Move engine to the left (port), using adjustment slot, (Figure 6) until gap no longer exists. Retighten engine mount to engine bed lag screws securely. 11. After correct alignment has been attained, re-check all mount fasteners to be sure that they are tight. 12. Loosen 2 bellows clamps on exhaust manifold elbow? (both sides). 13. Connect exhaust elbows to transom plate as shown in Figure 8. 14. Torque exhaust elbow to transom plate screws to specifications. 977 R 2 MERCRUISER REMOVAL-INSTALLATION-ALIGNMENT - 2B- 11 21. Connect Power Trim wires to engine and battery cables to battery. 22. Connect fuel line. 23. Install throttle cables, shift control wires, Power Steering and Power Trim hoses. Refer to instructions following (see "Index"). Figure 7. Coupling Nut Location 15. Retighten 2 bellows clamps on exhaust manifold elbows (both sides). 16. Exhaust elbow alignment MUST BE WITHIN ft" (6.35mm) in any direction. (Figure 8) If elbows are misaligned, recheck engine alignment and installation specifications. 17. Remove alignment shaft and plate. (Shaft should remove easily.) 18. Torque 6 rear mount compression stud nuts to specifications. (Figure 7) 19. Connect water inlet hose to water pump. Torque hose clamps to specifications. 20. Plug instrument harness connector onto engine harness receptacle. THROTTLE CABLE INSTALLATION IMPORTANT: Before proceeding with the following instructions, install throttle cable into remote control. Install control as outlined in instructions which accompany control. 1. Place remote control handle in neutral gear, idle position. 2. Connect cable end guide to throttle lever with screw, bushing, washers and nut. (Figure 9) 3. Grasp cable behind brass barrel and push lightly toward throttle lever. Adjust brass barrel to align with anchor stud and fasten barrel to stud with washers and nut. (Figure 9) Figure 9. Throttle Cable Installed 07490 Figure 8. Exhaust System Installation (LeftSide Shown) 977 R 2 MERCRUISER REMOVAL-INSTALLATION-ALIGNMENT - 2B- 11 POWER TRIM HOSE CONNECTIONS NOTE: Reverse lock valve and hoses are filled with oil. Make all connections as quickly as possible to prevent oil from draining out. 1. Connect gray Hose (from transom plate) to reverse lock valve as follows: (Figure 10) a. Remove shipping plug and plastic seal from reverse lock valve fitting. b. Remove shipping cap from end of hose and connect hose to reverse lock valve. 2. Connect black plastic hose (from trip pump) to reverse lock valve as follows: (Figure 10) a. Remove shipping plug from reverse lock valve fitting. b. Remove shipping cap from hose and connect hose to reverse lock valve. 3. For further Power Trim hose connections, refer to 07494A "Transom Plate Installation - Installing Hydraulic Pump Hoses" (use "Index"). Figure 10. Power Trim Hose Connections - Reverse Lock Valve SHIFT CONTROL WIRING CONNECTIONS IMPORTANT: Battery cables must be disconnected from battery prior to connecting shift control wiring to shift 12 Volt motor. Terminal Figure 12. Shift Control Wiring Connections To Remote Control Figure 13. Remote Control Connection 1. Remove shift motor cover. (Figure 1, preceding) 2. Connect ring terminals (located on shift control harness) to terminals on shift motor, matching lead and terminal colors. Fasten harness clamp to shift motor bracket. (Figure 12) Reinstall cover. 3. Connect white wire from remote control to 12-volt terminal (with white wire) on tachometer. (Figure 13) Use nut and insulating cap. 977 R 2 MERCRUISER REMOVAL-INSTALLATION-ALIGNMENT - 2B- 11 STERN DRIVE UNIT Removal 1. Disconnect rear end of trim cylinders from drive unit. 3. Carefully remove drive unit. 2. Support drive unit with suitable sling thru lifting eye on 4. Remove and discard drive shaft housing to bell housing top cover and remove 6 nuts which hold drive unit to bell gasket. housing. Stern Drive Installation CAUTION: Before installing stern drive unit, engine installation and alignment MUST BE completed and transmission output housing rear mount retaining nuts torqued to specification. 1. Lubricate the following with Multipurpose Lubricant (C-92-63250): Drive shaft housing pilot (Figure 1), "0 " ring and oil connectors (Figures 1 and 2). Apply a light coat of lubricant to inside surfaces of bell housing bore and position gasket. (Figure 2) 2. Lubricate U-joint shaft end (internally and externally) with Universal Joint Lubricant (C-92-74058). 3. Place forward anchor pin in gimbal ring. (Figure 2) Figure 2. Gasket Position on Bell Housing Studs Figure 1. Installation Lubrication Points NOTE: Use hoisting equipment to hold drive during installation. 4. Insert stern drive unit into bell housing bore (Figure3) by guiding universal joint shaft thru pilot bearing. NOTE: If necessary, support the U-joint front yoke with a length of stiff wire. 5. Push drive shaft housing completely into bell housing (Figure 5) and fasten with 6 elastic stop nuts and flat washers. (Figure 5) Torque to specification. NOTE: If universal joint shaft splines do not align with transmission splines, rotate propeller shaft slightly until drive can be pushed into bell housing. 977 R 2 Figure 3. Inserting Drive Unit into Gimbal Housing MERCRUISER REMOVAL-INSTALLATION-ALIGNMENT - 2B- 11 Installing Trim Cylinders 1. Place a flat washer, rubber bushing and one spiral spring on each side of forward anchor pin. 2. Install aft anchor pin, large washer, rubber bushing and one spiral spring on each side of aft anchor pin. (Figure 4) 3. Place cylinders on anchor pins. NOTE: Be sure that one small spiral spring is installed between rubber bushings on each side of both forward and Figure 5. Drive and Trim Cylinders Installed aft anchor pins. (Figure 4) They are required to ground cylinders to drive unit to reduce galvanic corrosion. 4. Place rubber bushings in forward and aft end of each cylinder. 01531 5. Place flat washer on each end of both anchor pins. Install nuts and tighten securely. (Figure 5) Installation CAUTION: Propeller MUST BE matched to stem drive rotation. Propeller shaft end is marked "RH " for right hand rotation propeller and "LH " for left hand rotation propeller. E-TR ALUMINUM PROPELLERS 1. Apply a liberal coat of Perfect Seal (C-92-34227) or waterproof-tvpe lubricant on splines of propeller shaft, especially if operated in salt water, to aid in removing at any future time. 2. Place thrust hub into propeller assembly (shoulder into recess of propeller). 3. While aligning splines, place jet-prop propeller (with thrust hub and splined hub assembly) on propeller shaft. (Figure 6) 4. Place propeller nut in recess of tab washer, thread propeller nut on propeller shaft and torque to specification. 5. Bend 3 of the tabs of tab washer down in grooves of spline washer to secure propeller nut. 2. In order, place splined washer (with bevel toward pro- H-TRS STAINLESS STEEL PROPELLERS peller), flat washer and propeller nut on prop shaft and 1. Place propeller on prop shaft (thrust hub is not required). tighten securely. Figure 4. Aft Anchor Pin Installed Propeller Figure 6. Installing and Removing Propeller 977 R 2 MERCRUISER REMOVAL-INSTALLATION-ALIGNMENT - 2B TRANSOM PLATE ASSEMBLY Removal IMPORTANT: Drive unit and engine must be removed prior to transom plate assembly removal. Refer to "Drive Unit Removal" and "Engine Removal" (use "Index"). 1. Remove steering link rod. (Figure 1) 2. Disconnect and remove steering cable from tube. (Fig. 1) 3. Remove (black) "up" hydraulic hose from trim pump, cap hose and plug hose connections. 4. Disconnect tilt limit switch from trim wiring harness. 5. Disconnect drive unit lubricant oil hose from lubricant reservoir. Plug hose with wooden plug and reinstall hose clamp. Also plug hose fitting in reservoir. 6. Remove nuts which hold inner and outer transom plates together, then remove inner transom plate and outer transom plate in that order. Figure 1. Transom Plate Installation MERCRUISER REMOVAL-INSTALLATION-ALIGNMENT - 2B- 11 977 R 2 Transom Plate Installation 1. Lubricate exhaust tube "0 " ring in gimbal housing assembly (Figure 2) and inner transom plate exhaust pilot. (Figure 3) Position them in transom holes, inserting switch leads, hydraulic hoses, unit oil hose and steering link rod thru openings in transom. Hold gimbaJ housing in position. Figure 3. Inner Transom Plate Exhaust Pilot Lubrication 2. Fasten gimbal housing and inner transom plate to transom with 8 flat washers and stop nuts, torquing them evenly to specifications (starting in the center and working up, then down). (Figure 1) 3. Remove wood plug and quickly slip drive oil hose and clamp over reservoir fitting and tighten clamp securely. 07495 Figure 2. Exhaust Tube "O" Ring Lubrication Installing Hydraulic Pump Hoses Remove cap from (black) "up" hose and plug from pump to IMPORTANT: Loop and tie down loose hose to avoid install hose. (Figure 1 ) rubbin9 or chafin9" NOTE: Refer to engine installation for connection of hydraulic hoses to reverse lock valve. Ride-Guide Steering Link Rod Installation 1. If steering link rod was removed, lubricate pivot area with Steering Link Rod Multipurpose Lubricant (92-63250) and connect steering link rod with pivot screw in rod, flat washer and curved washer to steering lever. (Figure 4) Align curved washer and secure with flat washer and castle nut. Torque castle nut to specification and install cotter pin. If hole in link rod does not align with nearest notch in castle nut, back Curved Washer Steering Arm nut off slightly until it aligns, then install cotter pin. 2. Secure steering link rod to adaptor inside hole with flat Flat Washer washer and castle nut. Torque castle nut to specification and install cotter pin. If hole in link rod does not align with nearest notch in castle nut, back nut off slightly until it aligns, then install cotter pin. Cotter Pin I > Figure 4. Connecting Steering Link Rod Mounting Steering Unit to Transom Plate Tromom Plot« 1. Apply thin coat of Quicksilver Multipurpose Lubricant Mounting toiws Mounting Tub« (C-92-63250) to attaching and mounting parts of Power Steering unit during assembly. 2. Insert mounting tube thru first transom boss. Thread jam nut fully onto tube and tighten securely, then insert mounting tube thru second boss. (Figure 5) NOTE: Left side Power Steering unit is installed on opposite side in same manner. Figure 5. Installing Mounting Tube - Right Side 977 R 2 MERCRUISER REMOVAL-INSTALLATION-ALIGNMENT - 2B 3. Lubricate Power Steering unit extension rod with Multipurpose Lubricant and insert rod thru mounting tube. (Figure 6) Thread mounting tube into Power Steering unit until jam nut bottoms against transom boss. (Figure 7) Using a I'/s" deep well socket, torque tube to 50 to 60 ft. lbs. (6.9 to8.3mkg),usingnutonend of mountingtube. Transom Plate Mounting Bosses Mounting Tube 07693 Figure 6. Installing Mounting Tube - Left Side 4. Turn adjusting screw in firmly against transom and secure with locknut. (Figure 8) Place guide slide over cable guide tube. 5. Attach cable end adaptor to extension rod with clevis pin, as shown in Figure 9. Secure clevis pin with cotter pin. 6. Install steering link rod to adaptor and secure with washer and castle nut. Torque nut to 20 to 25 in. lbs. (23 to 28 kg-cm), then secure castle nut with cotter pin (bend ears around nut). (Figure 9) (If necessary, back off nut until cotter pin can be installed.) 7. Lubricate cable guide tube with Multipurpose Lubricant (C-92-63250) and insert cable thru cable guide tube. Thread coupler nut onto guide tube and torque to 35 to 40 ft. lbs. (4.8 to 5.5mkg). Install locking sleeve on coupler nut and secure with cotter pin. (Figure 10) 8. Attach cable to cable end adaptor with clevis pin. (Figure 9) Secure clevis pin with cotter pin. Figure 7. Mounting Power Steering Unit IMPORTANT: This Power Steering Unit is shipped with the steering cable guide tube preset (to dimension shown in Figure 8) for cables with end dimensions called for by Mounting Tube Adjusting Nut Figure 8. Power Steering Unit Secured Coupler Extension Rod Cable End Adaptor \ Washer, \ Castle Nut 5, and Cotter Pin Nut \ 07690 Figure 9. Cable End Adaptor and Link Rod Attached to Dual Station Cable End Adaptor the BIA Certification Handbook. Therefore, only cables, which comply with the BIA Certification Handbook end dimensions, should be installed on this unit If cables with improper dimensions are installed, severe damage to the drive unit and/or steering system may result. DO NOT attempt to adjust steering cable guide tube, as guide tube adjusting nut and sleeve have been torqued with Loctite applied at the factory, and an attempt to loosen adjusting nut or sleeve may result in damage to tube. Lo I 04224 blade screwdriver. Remove gasket from seat. 1. Remove pump plunger from pump well. 10. Remove primary metering jets. DO NOT remove secondary 2. Remove air horn gasket from dowels on secondary side of metering plates. (Figure 7) bowl, then remove gasket from around power piston and 11. Remove pump discharge check ball retainer and check ball. primary metering rods. (Figure 7) MERCRUISER FUEL SYSTEMS - 4B-29 12. Remove baffle from secondary side of bowl. (Figure 7) 13. Remove vacuum hose from vacuum break assembly and from tube connection on bowl. (Figure 7) 14. Remove retaining screw from choke assembly and remove assembly from float bowl. NOTE: If further disassembly of choke is necessary, remove clip from vacuum break link at vacuum break lever, then remove rod from vacuum break lever. Spread retaining ears on bracket next to vacuum break assembly, then remove vacuum break assembly from lever. Figure 6. Float Bowl Disassembly 15. Remove fast idle cam from choke assembly. 16. Remove lower choke rod and actuating lever from float bowl well. 17. Remove fuel inlet filter nut, gasket, filter and spring. 18. Remove screws which fasten throttle body to float bowl. (Figure 8) Separate pieces and remove bowl to body- insulator gasket. THROTTLE BODY DISASSEMBLY 1. Rotate pump rod and remove rod from primary throttle lever. 2. Remove idle mixture screws and springs. CLEANING and 1. Clean carburetor in a cold immersion-type cleaner, such as Carbon-X (X-55) or equivalent. CAUTION: Any rubber parts, plastic parts, diaphragms and pump plungers should not be immersed in carburetor cleaner. The delrin cam on air valve shaft, however, will withstand normal cleaning in carburetor cleaner. 2. Blow out all passages in castings with compressed air. Do not pass drills thru jets or passages. IMPORTANT: Further disassembly of throttle body is not required. Extreme care must be taken to avoid damaging secondary throttle valves. INSPECTION 3. Inspect idle mixture needles for damage. 4. Examine float needle and seat for wear. If worn, replace with new inlet needle and seat assembly. 5. Inspect upper and lower surfaces of carburetor castings for damage. 6. Inspect holes in levers for excessive wear or out-of-round condition. If worn, replace levers. 7. Examine fast idle cam for wear or damage. 8. Check air valve for binding condition. If air valve is damaged, replace air horn assembly. 9. Check all throttle levers and valves for binds or other damage. 4B-30 - MERCRUISER FUEL SYSTEMS 774 REASSEMBLY THROTTLE BODY REASSEMBLY 1. Install idle mixture needles and springs until seated. Back out needles 2 turns as a preliminary idle adjustment. 2. Install pump rod in lower hole of throttle lever by rotating rod. FLOAT BOWL REASSEMBLY 1. Install new throttle body to bowl insulator gasket. Be certain that gasket is properly installed over 2 locating dowels on bowl. 2. Install throttle body. Be sure that throttle body is properly- located over dowels on float bowl, then install throttle body to bowl screws and tighten evenly and securely. Place carburetor on proper holding fixture. 3. Install fuel inlet filter, new gasket and inlet nut and tighten nut securely. NOTE: If vacuum break diaphragm was removed from bracket, slide vacuum break diaphragm between retaining ears to hold securely. Install vacuum break rod (LJ-bend end) in diaphragm link with end toward bracket, then install grooved end of rod in hole of actuating lever and retain to vacuum break lever with spring clip. 4. Install fast idle cam on vacuum break assembly. Be sure that fast idle cam pick-up lever on intermediate choke shaft is located in cut-out area of fast idle cam. 5. Connect choke rod to choke rod actuating lever (plain end). Hold choke rod (with grooved end pointing inward) and position choke rod actuating lever in well of float bowl. Install choke assembly, engaging shaft with hole in actuating lever. Install retaining screw and tighten securely. Remove choke rod from lever for installation later. 6. Install vacuum hose to tube connection on bowl and vacuum break assembly. 7. Install air deflector in secondary side of bowl with notches toward top. 8. Install pump discharge check ball and retainer in passage next to pump well. 9. Install primary main metering jets. 10. Install fuel inlet needle seat and gasket. Use wide blade screwdriver to avoid distortion. Place inlet needle in position in seat. 11. Using needle-nose pliers to hold needle pull clip, install pull clip on needle. Pull clip is properly positioned with open end toward front of bowl. 12. Install float by sliding float lever under pull clip from front to back. With float lever in pull clip, hold float assembly at toe and install retaining pin from pump well side. Be careful not to distort pull clip. 13. Adjust float level as outlined under "Adjustments", following. 14. Install power piston spring in power piston well. If primary main metering rods were removed from hanger, reinstall and make sure that tension spring is connected to top of each metering rod. Install power piston assembly in well with metering rods properly positioned in metering jets. Press down firmly on power piston to ensure engagement of retaining clip. 15. Install plastic insert over float assembly, pressing downward until seated properly. 16. Install pump return spring in pump well. 17. Install air horn gasket around primary metering rods and piston. Position gasket over 2 dowels on secondary side of bowl. 18. Install pump plunger in pump well. AIR HORN REASSEMBLY 1. Install the following, if removed: Pump lever and retain with roll pin, choke shaft, choke valve and 2 attaching screws. 2. Install secondary metering rods. With air valve held wide open, rods should be positioned with upper ends thru hanger holes and toward each other. AIR HORN to BOWL INSTALLATION 1. Carefully place air horn assembly on bowl, positioning secondary- metering rods, vent tubes and accelerating well tubes thru air horn gasket. When installing, be certain that pump plunger is positioned properly thru air horn. To prevent distortion of secondary metering plates, do not force air horn assembly onto float bowl. A slight sideward movement will center metering rods in metering plates. 2. Install 4 long air horn screws around secondary side, 2 short screws in center section and one short screw above fuel inlet. Two counter-sunk screws are installed in primary venturi area. Tighten all screws evenly and securely. (Figure 9) 3. Connect pump rod to pump lever and retain with spring clip. 4. Connect choke rod to lower choke lever and upper choke lever. Install spring clip on upper end of rod. Figure 9. Quadrajet Air Horn Screw Tightening Sequence 5. Connect vacuum break link rod to air valve lever and vacuum break stem. Install spring clip in groove on vacuum break end of link rod. 6. Check following adjustments as outlined: a. Pump adjustment. b. Choke rod adjustment. c. Air valve dashpot adjustment. d. Vacuum break adjustment. e. Unloader adjustment. f. Air valve lockout adjustment. g. Secondary opening adjustment. h. Secondary closing adjustment. i. Secondary metering rod adjustment, j. Air valve spring adjustment. MERCRUISER FUEL SYSTEMS - 4B-31 INSTALLATION 1. Place baffle plate and new base gasket in position on WARNING: After installation of carburetor, manually intake manifold. operate throttle for full open and close position to 2. Fasten carburetor to manifold, using fasteners which were check for a binding or sticking condition of the removed previously. throttle linkage. This is especially important in applica 3. Connect throttle linkage. tions that include dashpots and other throttle actuated 4. Connect fuel line. mechanisms. It may be necessary to remove and 5. Adjust choke. replace these mechanisms and carburetor throttle 6. Install flame arrester. linkage parts on this carburetor. Failure to follow these 7. Adjust idle speed and mixture. procedures may result in uncontrolled engine speed. ADJUSTMENTS Following adjustments can be completed with carburetor installed on engine. Make adjustments in sequence listed. Adjustment specifications follow. FLOAT LEVEL (Figure 10) 1. Remove flame arrestor from carburetor. 2. Remove air horn from float bowl as outlined under "Disassembly", preceding. 3. Measure from top of float bowl gasket surface (gasket removed) to top of float at toe (locate gauging point 1/16" [1.6mm] back from toe). Do not gauge on numbers on float. NOTE: Make sure that retaining pin is held firmly in place and that float tang is seated on float needle. 4. Bend float arm up or down, as required, to obtain dimension specified. 5. Reinstall air horn as outlined under "Air Horn to Bowl Installation". Figure 10. Float Level Adjustment PUMP ADJUSTMENT (Figure 11) 1. Disconnect secondary actuating link. 2. With throttle valves completely closed and pump rod in specified hole in lever, measure from top of choke valve wall (next to vent stack) to top of pump stem. 3. Bend pump lever to obtain dimensions specified. 4. Connect actuatin» link. Figure 11. Pump Adjustment CHOKE ROD ADJUSTMENT (Figure 12) 1. Place cam follower on second step of fast idle cam and against high step. Rotate choke valve toward closed position by pushing down lightly on vacuum break lever. 2. Dimension between lower edge of choke valve and air hom wall should be as specified. Bend choke rod to adjust. Figure 12. Choke Rod Adjustment AIR VALVE DASHPOT ADJUSTMENT (Figure 13 Push vacuum break stem in until diaphragm is seated. Clearance, as specified, must exist between dashpot rod and end of slot in air valve lever. Bend rod at air valve end to adjust. 4B-32 - MERCRUISER FUEL SYSTEMS Figure 13. Air Valve Dashpot Adjustment VACUUM BREAK ADJUSTMENT (Figure 14) 1. Push vacuum break stem in until diaphragm is seated and hold choke valve toward closed position. 2. Dimension between lower edge of choke valve and air hom wall should be as specified. Bend vacuum break tang to adjust. Figure 14. Vacuum Break Adjustment UNLOADER ADJUSTMENT (Figure 15) 1. With choke valve held in closed position by a rubber band on vacuum break lever, open primary throttle valves to wide open position. 2. Dimension between edge of choke valve and air horn wall should be as specified. Bend fast idle lever tang to adjust. Figure 15. Unloader Adjustment AIR VALVE LOCKOUT ADJUSTMENT (Figure 16) 1. Open choke valve to wide open position by rotating vacuum break lever. Choke rod must be to top of slot in choke lever. 2. Dimension between front edge of air valve and lockout lever tang must be as specified. Bend upper end of lockout lever tang to adjust Figure 16. Air Valve Lockout Adjustment SECONDARY OPENING ADJUSTMENT (Figure 17) 1. Open primary throttle valves until actuating link contacts tang on secondary lever. With valves in this position, dimension between link and tag on secondary lever should be as specified. 2. Bend tang on secondary lever to adjust. Figure 17. Secondary Opening Adjustment SECONDARY CLOSING ADJUSTMENT (Figure 18) 1. Set idle speed screw to recommended RPM. 2. Dimension between actuating link and front of slot in Figure 18. Secondary Closing Adjustment MERCRUISER FUEL SYSTEMS - 4B-33 secondary lever should be as specified when tang on throttle lever is against actuating lever. 3. Bend tang on throttle lever to adjust. SECONDARY METERING ROD ADJUSTMENT (Figure 19) 1. Measure from top of metering rod to top of air horn casting next to flame arrestor stud hole. Dimension must be as specified. 2. To adjust, bend metering rod hanger at point shown. Both rods must be adjusted to same dimension. Figure 19. Secondary Metering Rod Adjustment AIR VALVE SPRING ADJUSTMENT (Figure 20) 1. Loosen alien head lockscrew and turn adjusting screw counterclockwise to remove all spring tension. 2. With air valve closed, turn adjusting screw clockwise number of turns which are specified after torsion spring contacts pin on shaft. Hold adjusting screw in this position and tighten lockscrew. Figure 20. Air Valve Spring Adjustment CHOKE COIL ROD ADJUSTMENT (Figure 21) 1. With choke valve completely closed and choke rod at bottom of choke lever slot, pull choke coil rod up to end of travel. 2. Rod should be positioned as shown. Bend choke coil rod to adjust. Figure 21. Choke Coil Rod Adjustment IDLE SPEED and MIXTURE ADJUSTMENTS 1. Be sure that flame arrestor is installed. 2. Start engine and allow to run until normal operating temperature is reached and choke is fully open. 3. Stop engine; disconnect throttle cable from engine. 4. Start engine. Adjust idle speed screw to obtain recommended idle RPM as indicated in "Specifications" Section 8. 5. Adjust idle mixture screw(s). IMPORTANT: Do not turn idle mixture screw(s) tightly against stop, or mixture needle and/or seat will be damaged. 6. Stop engine; turn idle mixture adjusting needles in until they very lightly just touch adjusting needle seat, then back needles off seats the specified number of turns for preliminary idle adjustment. 7. Start engine and run at idle RPM. Adjust idle mixture needle for highest, steadiest manifold vacuum reading. If a vacuum gauge is not available, obtain smoothest running, maximum idle speed by turning idle adjusting needle in until engine RPM begins to drop off, then backing needle off over "high spot" until engine RPM again drops off. Set idle adjusting needle halfway between the 2 points for satisfactory idle mixture setting. Repeat procedure with other needle. Should these adjustments show an increase in idle RPM, reset idle speed adjusting screw to obtain specified idle RPM and again adjust idle mixture adjusting needle. 8. Stop engine and install throttle cable, following. Check that throttle valves are fully open when remote control is in full forward position. 9. Shift unit into forward gear and re-adjust idle speed screw to obtain recommended idle RPM. WARNING: Check all fuel connections for leaks. 4B-34 - MERCRUISER FUEL SYSTEMS ENGINE MERCRUISER Section 5 TABLE of CONTENTS Page Page Engine Mechanical • 4 and 6-Cylinder Models 5A-1 General 5A-1 Tools 5A-1 Exhaust Manifold 5A-1 Exhaust Water Shutter 5A-2 Rocker Arm Cover 5A-2 Valve Mechanism 5A-3 Valve Adjustment 5A-3 Valve Lifters 5A-4 Valve Stem Oil Seal and/or V^lve Spring 5A-6 Cylinder Head Assemblies 5A-8 Cylinder Head Assemblies and Valve Conditioning . . 5A-8 Oil Pan 5A-11 Oil Pump 5A-12 Crankshaft Pulley 5A-13 Torsional Damper 5A-13 Crankcase Front Cover 5A-14 Oil Seal (Front Cover) 5A-14 Flywheel and Coupler 5A-15 Oil Seal (Rear Main) 5A-16 Main Bearings 5A-17 Connecting Rod Bearings 5A-18 Connecting Rod and Piston Assemblies 5A-19 Piston Rings 5A-22 Crankshaft 5A-24 Camshaft 5A-24 Camshaft Bearings 5A-27 Cylinder Block 5A-29 Distributor Lower Bushing 5A-30 Oil Nozzle Replacement 5A-31 Oil Filter Bypass Valve and Replacement 5A-31 Engine Mechanical - V-8 (302 and 351 Cu. In.) Ford Engines 5B-1 Tools 5B-1 General 5B-1 Intake Manifold 5B-1 Exhaust Manifolds 5B-2 Rocker Arm Cover 5B-3 Valve Clearance 5B-3 Valve Mechanism 5B-4 Hydraulic Valve Lifters 5B-5 Valve Spring, Retainer and Stem Seal Replacement. 5B-6 Cylinder Head 5B-7 Oil Pan 5B-13 Oil Pump 5B-13 Flywheel 5B-15 Piston Assembly 5B-16 Connecting Rods 5B-19 Crankshaft 5B-20 Main Bearings 5B-24 Connecting Rod Bearings 5B-25 Main and Connecting Rod Bearing Inserts 5B-26 Torsional Damper 5B-27 Cylinder Block Front Cover and Front Seal 5B-27 Timing Chain, Sprockets and Fuel Pump Eccentric .5B-28 Camshaft 5B-30 Camshaft Bearing Replacement 5B-30 Camshaft Lobe Lift 5B-31 Camshaft End Play 5B-32 Cylinder Block 5B-32 Repairing Cylinder Block 5B-34 Core Plug Replacement 5B-34 Engine Mechanical - V-8 GM Engines 5C-1 Tools 5C-1 General 5C-1 Rocker Arm Cover 5C-1 Exhaust Manifolds 5C-2 Intake Manifold 5C-3 Valve Mechanism 5C-4 Hydraulic Valve Lifters 5C-5 Valve Stem Oil Seal and/or Valve Spring 5C-7 Cylinder Head 5C-8 Cylinder Head and Valve Conditioning 5C-8 Oil Pan 5C-12 Oil Pump 5C-12 Torsional Damper 5C-13 Crankcase Front Cover 5C-14 Flywheel 5C-15 Oil Seal (Rear Main) 5C-15 Main Bearings 5C-16 Connecting Rod Bearings 5C-18 Connecting Rod and Piston Assembly 5C-19 Crankshaft 5C-23 Timing Chain and/or Sprockets 5C-25 Camshaft 5C-25 Crankshaft Sprockets 5C-26 Camshaft Bearings 5C-27 Cylinder Block 5C-28 Engine Mechanical-470 Model 5D-1 General 5D-1 Tools 5D-1 Removal/Disassembly/Cleaning-lnspection/Reassembly/ lnstallation 5D-2 Exhaust Tube Water Shutter 5D-2 Exhaust Manifold 5D-2 Intake Manifold 5D-3 Rocker Arm Cover 5D-5 Valve Clearance 5D-5 Valve Mechanism 5D-5 Hydraulic Valve Lifters 5D-6 Valve Spring, Retainer or Stem Seal Replacement (with Cylinder Head Installed) 5D-7 Cylinder Head and Valves 5D-8 Alternator Rotor 5D-12 Stator 5D-12 Front Cover and/or Water Pump Shaft and Front Front Cover Oil Seals 5D-13 Timing Chain and Sprockets 5D-14 Timing Chain Deflection 5D-14 EngineCouplerand/orFlywheel 5D-15 Oil Pan 5D-15 Oil Pump 5D-15 Oil Seal (Rear Main) 5D-17 Camshaft 5D-18 Camshaft Gear Replacement 5D-19 Camshaft Bearings 5D-19 Crankshaft 5D-19 Main Bearings 5D-22 Connecting Rod Bearings 5D-23 Piston and Rod Assembly 5D-25 Cylinder Block 5D-29 SECTION 5 - ENGINE PART A - ENGINE MECHANICAL. IN-LINE A BRUNSWICK COMPANY Pa9e Installation 5A-1« Oil Seal (Front Cover) 5A-14 Replacement 5A-14 With Cover Removed 5A-14 Without Cover Removed 5A-14 Flywheel and Coupler 5A-15 Removal 5A-15 Inspection 5A-15 Engine Coupling 5A-15 Flywheel 5A-15 Installation 5A-15 Oil Seal (Rear Main) 5A-16 Replacement 5A-16 Main Bearings 5A-17 Inspection 5A-17 Checking Clearance 5A-17 Main Bearing Replacement 5A-18 Connecting Rod Bearings 5A-18 Inspection and Replacement 5A-18 Connecting Rod and Piston Assemblies 5A-19 Removal 5A-19 Disassembly (Method "1") 5A-20 Disassembly (Method "2") 5A-20 Cleaning and Inspection 5A-21 Connecting Rods 5A-21 Pistons 5A-21 Piston Pins 5A-21 Reassembly (Method "1") 5A-21 Reassembly (Method "2") 5A-22 Piston Rings 5A-22 Installation 5A-23 Crankshaft 5A-24 Removal 5A-24 Cleaning and Inspection 5A-24 Installation 5A-24 Camshaft 5A-24 Measuring Lobe Lift 5A-24 Removal 5A-25 Inspection 5A-25 Camshaft Gear Replacement 5A-25 Installation 5A-26 Camshaft Bearings 5A-27 Removal 5A-27 Installation 5A-27 CylinderBlock 5A-29 Cleaning and Inspection 5A-29 Repairs 5A-29 CylinderConditioning 5A-29 Cylinder Boring 5A-29 Cylinder Honing 5A-29 Piston Selection 5A-30 Oversize Pistons Available 5A-30 Distributor Lower Bushing 5A-3C Inspection and Replacement 5A-30 Oil Nozzle Replacement 5A-31 Oil Filter Bypass Valve and Replacement 5A-31 Engine Mechanical - 4 and 6-Cylinder ModelsGeneralTools Exhaust Manifold Removal Cleaning and Inspection Installation Exhaust Water Shutter Rocker Arm Cover Removal Installation Valve Mechanism Removal Installation Valve Adjustment Engine Stopped Engine Running Valve Lifters Locating Noisy Lifters Removal Servicing Disassembly Cleaning and Inspection Reassembly Installation Valve Stem Oil Seal and/or Valve SpringReplacementCylinder Head Assemblies Removal Installation Cylinder Head Assemblies and Valve Conditioning .... 5A-8 INDEX Page 5A-1 5A-1 5A-1 5A-1 5A-2 5A-2 5A-2 5A-2 5A-2 5A-2 5A-2 5A-3 5A-3 5A-3 5A-3 5A-3 5A-3 5A-4 5A-4 5A-4 5A-4 5A-4 5A-4 5A-4 5A-6 5A-6 5A-6 5A-8 5A-8 5A-8 Disassembly Cleaning Inspection Rocker Arm Studs Valve Guide Bores Valve Seats Valves Reassembly Oj| panRemovalInstallation Oil PumpRemovalDisassemblyCleaning and InspectionReassemblyInstallation Crankshaft PulleyRemovalInstallation Torsional DamperRemovalInstallation Crankcase Front CoverRemoval 5A-8 5A-8 5A-9 5A-9 5A-10 5A-10 5A-10 5A-11 5A-11 5A-11 5A-11 5A-12 5A-12 5A-12 5A-12 5A-12 5A-12 5A-13 5A-13 5A-13 5A-13 5A-13 5A-13 5A-14 5A-14 ENGINE MECHANICAL - 4 and 6-CYLINDER MODELS GENERAL Some Repairs, Listed in This Section, Must Be Completed with Engine Removed from Boat Engine Removal Depends Upon Type of Repair and Boat Design. Place Engine on Engine Stand for Major Repairs. In-line engines with 153, 181, and 250 cu. in. displacements are covered in this section. Full pressure lubrication thru a full flow oil filter is furnished by a gear-type oil pump. Distributor, driven by a helical gear on camshaft, drives oil pump. Main oil gallery feeds oil thru drilled passages to camshaft and crankshaft to lubricate bearings. Main oil gallery also feeds valve lifters which, thru push rods, feed individually-mounted rocker arms. Cubic inch (and metric equivalent) displacement of each MerCruiser model is listed below. No. of Model Cylinders Displacement MerCruiser 120 4 153 Cu. In. (2507cc) MerCruiser 140 4 181 Cu. In. (2966cc) MerCruiser 165 6 250 Cu. In. (4097cc) TOOLS All "J-" (Special) Tools Listed in This Section May be Purchased from: Kent-Moore, Inc. 28635 Mound Road Warren, Mich. 48089 EXHAUST MANIFOLD 1 - Bolt (4) 2 - Washer (4) 3 - Screw 4-Nut (2) 5 - Washer (2) 6 - Bolt (4) 7 - End Cap (Front) 8 - Gasket 9 - Exhaust Heat Tube 10-Stud (2) 11 - Gasket 12-Plug (4) 13 - Water Drain Plug 14 - Lockwasher (4) 15-Nut (4) 16 - Exhaust Elbow 17 - Water Separation Tube 18 - Gasket 19 - Stud (4) 20 - Exhaust Manifold 21 - Gasket 22 - End Cap (rear) 23 - Bolt (4) 24 - Water Drain Plug 25 - Plug (2) 26 - Wiring Harness Clamp 27 - Lockwasher (1) 28 - Screw (1) 29 - Plug Figure 1. Typical Exhaust Manifold Assembly 977 R1 MERCRUISER ENGINE - 5A-1 REMOVAL 1. Drain water from block, exhaust manifold and exhaust elbow. 2. Disconnect throttle cable at carburetor. 3. Disconnect exhaust hose and cooling hose. 4. Disconnect fuel line at carburetor. 5. Disconnect crankcase ventilation hose at rocker arm cover. 6. Remove wiring harness clamps from manifold. 7. Disconnect alternator bracket from manifold. 8. Remove exhaust manifold fasteners; remove manifold assembly and discard gaskets. 9. Check for cracks in manifold castings. 10. If exhaust manifold requires replacement, transfer intake manifold (if applicable) and carburetor to new exhaust manifold. CLEANING and INSPECTION 1. Clean gasket material from all surfaces and wash parts in solvent 2. Inspect all parts carefully. Machined surfaces must be clean and free of all marks and deep scratches, or water and exhaust leaks may result. 3. Check water passages for sand, silt or foreign material. Passages must be clean for efficient cooling. 4. If more thorough inspection is desired, pipe plugs may be removed from exhaust manifold elbow and exhaust pipe elbow. EXHAUST 1 The engine is equipped with exhaust shutter in exhaust tube, it may make a rattling noise at idle speed. This noise is caused by a loose fit between shutter shaft and support brackets and can be corrected as follows: 1. Drain water from exhaust manifold and elbow. 2. Loosen hose clamps which fasten exhaust bellows to exhaust tube. 3. Remove nuts, which fasten exhaust elbow to manifold, and remove elbow and bellows. Scrape gasket material from manifold and elbow. 4. Thoroughly clean area between shutter support brackets and exhaust tube with cleaning solvent and a small brush or pipe cleaner. 5. Fill entire area between support brackets and tube with Sealant (C-92-52238). (Figure 2) Allow sealant to cure for 24 hours. 6. Reinstall elbow (using new gasket) and connect bellows. Tighten hose clamps securely. NOTE: If plugs are removed, coat threads with Sealant (C-92-52238) before reinstalling. INSTALLATION 1. Clean gasket surfaces on cylinder head and manifold. 2. Position new gasket on head and carefully install manifold in position, making sure gasket is in place. 3. Install fasteners while holding manifold in place. 4. Tighten evenly and securely, starting in center and working out toward ends. NOTE: Vibration will occur if fasteners (which secure manifold to cylinder head) loosen from compression of manifold to head gasket. 5. Connect crankcase ventilation hose at rocker arm cover. 6. Install alternator bracket to manifold. 7. Install wiring harness and clamps to manifold. 8. If exhaust manifold was replaced, transfer intake manifold (if applicable) and carburetor to new exhaust manifold. 9. Connect throttle cable at carburetor. 10. Connect fuel line and choke tube. 11. Reinstall exhaust hose and cooling hose. 12. Start engine, check for leaks and adjust carburetor idle speed and mixture. SHUTTER Figure 2. Sealant Application ROCKER ARM COVER REMOVAL 1. Disconnect crankcase ventilation hose at rocker arm cover. 2. Disconnect and remove fuel line. 3. Remove attaching bolts. 4. Remove rocker arm cover and gasket. INSTALLATION 1. Clean gasket surfaces on cylinder head and rocker arm © j 5A-2 - MERCRUISER ENGINE cover with degreaser, then, using a new gasket, install rocker arm cover and torque to specifications. NOTE: Wiring harness and inlet hose clips must be installed under their proper screws. 2. Connect crankcase ventilation hoses. 3. Replace fuel line. Tighten connections securely and check for leaks. VALVE MECHANISM 2. Remove rocker arm nuts, rocker arm balls, rocker arms and push rods. NOTE: Place rocker arms, rocker arm balls and push rods in a rack so that they may be reinstalled in same location. 1 - Nut 2 - Ball Unit 3 - Rocker Arm INSTALLATION 4 - Push Rod 5 - Rocker Arm Stud NOTE: Whenever new rocker arms and/or rocker arm balls are being installed, coat bearing surfaces of rocker arms and rocker arm balls with engine oil. 1. Install push rods. Be sure that push rods seat in lifter socket. Figure 3. Valve Mechanism 2. Install rocker arms, rocker arm balls and rocker arm nuts. Tighten rocker arm nuts until all lash is eliminated. REMOVAL 3. Install rocker arm cover as outlined. 1. Remove rocker arm cover as outlined. 4. Adjust carburetor idle speed and mixture. VALVE ADJUSTMENT ENGINE STOPPED can be adjusted with engine in this position: No. 2 Cylinder-Exhaust 1. Remove valve cover as outlined. No. 3 Cylinder-Intake 2. Adjust valves when lifter is on low lobe of camshaft, as No. 4 Cylinder-Exhaust follows: No. 5 Cylinder-Intake (6-Cvl. Only) a. Mark distributor housing with chalk at No. 1 and No. 6 No. 6 Cylinder-Intake and Exhaust (6-Cyl. Only) cylinder spark plug wire location for 6-cylinder engine 3. Install distributor cap, spark plug wires and coil lead. and No. 1 and No. 4 for 4-cylinder engine. Disconnect Install rocker arm cover as outlined. 4. plug wires at spark plugs and coil and remove 5. Adjust carburetor. distributor cap and plug wire assembly (if not previously done). NOTE: Valves are numbered as follows (starting from front of engine): No. 1 -Exhaust No. 4 -Intake No. 1 -Intake No. 4 -Exhaust No. 2 -Intake No. 5 - Exhaust, No. 2-Exhaust No. 5 -Intake 6-Cyl. Only No. 3 -Exhaust No. 6 -Intake No. 3 -Intake No. 6 -Exhaust' b. Use remote starter switch to crank engine until distributor rotor points to No. 1 cylinder position and breaker points are open. Following valves can be adjusted with engine in No. 1 Firing position. No. 1 Cylinder-Exhaust and Intake No. 2 Cylinder-Intake No. 3 Cylinder-Exhaust No. 4 Cylinder-Intake ENGINE RUNNING No. 5 Cylinder-Exhaust (6-Cyl. Only) c. Back out adjusting nut until lash is felt at push rod. Following procedure should be completed only if readjust- then turn in adjusting nut until all lash is removed. ment is required. This can be determined by checking push rod end plav (up and down) while turning adjusting nut. (Figure 4) 1. Run engine until it reaches normal operating temperature, When play is removed, turn adjusting nut in % then remove valve cover. additional turn. With engine running at idle, back off valve rocker arm nut d. Crank engine until distributor rotor points to No. 6 until valve rocker arm starts to clatter. (Figure 4) position for 6-cylinder engine and No. 4 for 4-cvlinder 3. Turn rocker arm nut down slowly until clatter just stops. engine (and breaker points are open). Following valves This is zero lash position. 01590 977 R1 MERCRUISER ENGINE - 5A-3 4. Turn nut down !4 additional tum and pause 10 seconds possible interference between inlet valve head and top of until engine runs smoothly. Repeat additional J4 turns, piston which might result in internal damage and/or bend pausing 10 seconds each time, until nut has been turned push rods. down % turn from zero lash position. NOTE: This 3A turn pre-load adjustment must be done 5. Repeat Steps 2-3-4 to adjust other valves. slowly to allow lifter to adjust itself, thus preventing 6. Install valve cover, using new gasket. VALVE LIFTERS Refer to Figure 5 for parts identification. Hydraulic valve lifters seldom require attention. Lifters are simple in design, readjustments are not necessary and lifter servicing requires only that care and cleanliness be exercised in handling of parts. LOCATING NOISY LIFTERS Use a piece of garden hose approximately 4 ft. (1.22m) in length to locate a noisy valve lifter. Place one end of hose near end of each intake and exhaust valve, with other end of hose to the ear. Sound, thus, is localized, making it easy to determine which lifter is at fault. Another method is to place a finger on face of valve spring retainer. If lifter is not functioning properly, a distinct shock will be felt when valve returns to its seat. General types of valve lifter noise are: 1. Hard Rapping Noise - Usually caused by plunger becoming tight in bore of lifter body to such an extent that return spring can no longer push plunger back up to working position. Probable causes are a. Excessive varnish or carbon deposit which causes abnormal stickiness. b. Galling or "pickup" between plunger and bore of lifter body, usually caused by an abrasive piece of dirt or metal wedging between plunger and lifter body. 2. Moderate Rapping Noise - Probable causes are a. Excessively high leakdown rate. b. Leaky check valve seat. c. Improper adjustment. 3. General Noise Throughout Valve Train - This, in most cases, will be a definite indication of insufficient oil supply or improper adjustment. 4. Intermittent Clicking - Probable causes are a. A microscopic piece of dirt momentarily caught between ball seat and check valve ball. b. In rare cases, ball itself may be out- of-round or have a flat spot. c. Improper adjustment. In most cases, where noise exists in one or more lifters, all lifter units should be removed, disassembled, cleaned in a solvent, reassembled and reinstalled in engine. If dirt, varnish, carbon, etc, are shown to exist in one unit, it likely exists in all units. Thus, it would be only a matter of time before all lifters cause trouble. REMOVAL 1. Remove valve mechanism as outlined. 2. Mark distributor housing with chalk at each cylinder position (plug wire), then disconnect plug wires at spark plugs and coil and remove distributor cap and plug wire assembly. 3. Crank engine until distributor rotor points to No. 1 position, then disconnect distributor primary lead at coil and remove distributor. 4. Remove push rod covers (discard gaskets). 5. Remove valve lifters. NOTE: Place valve lifters in a rack so they may be reinstalled in same location. SERVICING Two types of hydraulic lifters are used. Both types operate on same principle and are serviced basically in same manner. Complete lifter assemblies are interchangeable, but parts from one lifter are not interchangeable with another. Both lifters are easilv identified by outside configuration of lifter body. Identify them as lifter "A " and lifter "B". (Figure 5) DISASSEMBLY 1. Hold plunger down with push rod and remove push rod seat retainer with blade of small screwdriver. 2. Remove push rod seat and metering valve (lifter "A") or push rod seat and inertia valve assembly (lifter "B"). (Figure 5) 3. Remove plunger, ball check valve assembly and plunger spring. 4. Remove ball check valve and spring by prying ball retainer loose from plunger with blade of small screwdriver. (Figure CLEANING and INSPECTION Thoroughly clean all parts in cleaning solvent and inspect parts carefully. If any parts are damaged or worn, entire lifter assembly should be replaced. If outside of lifter body is scuffed or worn, inspect cylinder block lifter bore. If bottom of lifter is scuffed or worn, inspect camshaft lobe. If push rod seat is scuffed or worn, inspect push rod. NOTE: Do not remove inertia valve and retainer (lifter "B") (Figure 5) from push rod seat. To check valve, shake push rod seat and inertia valve assembly. Vahe should move. REASSEMBLY 1. Place check ball on small hole in bottom of plunger. 5A-4 - MERCRUISER ENGINE 2. Insert check ball spring on seat in ball retainer and place retainer over ball so that spring rests on ball. Carefully press retainer into position in plunger with blade of a small screwdriver. (Figure 7) CAUTION: Do not attempt to force or pump the plunger. 3. Place plunger spring over ball retainer and slide lifter body over spring and plunger, being careful that oil feed holes in lifter body and plunger line up. LIFTER "A" LIFTER "B" Small Screwdriver Figure 6. Removing Ball Check Valve 4. Fill assembly with oil, then insert end of a 1/8" (3.2mm) drift pin into plunger and press down strongly. At this point, oil holes in lifter body and plunger assembly will be aligned. (Figure 8) 5. Insert a 1/16" (1.6mm) drift pin thru both oil holes to hold plunger down against lifter spring tension. (Figure 8) NOTE: On lifter "B" (Figure 5), drift pin must not extend inside plunger. 6. Remove 1/8" drift pin and refill assembly with oil. 7. Install metering valve and push rod seat (lifter "A" ) or push rod seat and inertia valve assembly (lifter "B"). (Figure 5) 8. Install push rod seat retainer, press down on push rod seat and remove 1/16" drift pin from oil holes. Lifter now is completely assembled, filled with oil and ready for installation. LIFTER "A" LIFTER 'B" oeo30 Figure 5. Hydraulic Valve Lifters 1 - Lifter Body 5 - Check Ball Retainer 2 - Push Rod Seat 6 - Push Rod Seat Retainer 3 Metering Valve (Lifter "A") 7 - Plunger Inertia Valve (Lifter "B") 8 - Check Ball Spring 4 - Check Ball 9 - Plunger Spring 977 R1 NOTE: Before installing a new lifter, coat bottom of lifter with engine oil. Figure 7. Installing Ball Check Valve MERCRUISER ENGINE - 5A-5 05027 Oil Feed 1 /8" Drift Pin 05027 Oil Feed 1 /8" Drift Pin INSTALLATION 1. Install valve lifters. NOTE: Whenever valve lifters are being installed, co< bottom of valve lifters with engine oil. 2. Install push rod covers, using new gaskets, and torque to specifications. 3. Install distributor, positioning rotor to No. 1 cylinder position, then connect primary lead at coil. 4. Install distributor cap and high tension wires. 5. Install and adjust valve mechanism as outlined. 6. Adjust ignition timing with timing light and adjust carburetor idle speed and mixture. ^^ Figure 8. Assembling Hydraulic Lifters VALVE STEM OIL SEAL and/or VALVE SPRING 1 - Valve 2 - Valve Spring 3 - Valve Spring Shield 4 - Seal 5 - Cap 6 - Keys (2 per valve) Tool J-5892 Figure 9. Valve Spring and Related Parts REPLACEMENT 1. Remove rocker arm cover as outlined. Figure 10. Air Adaptor Tool 5A-6 - MERCRUISER ENGINE Figure 11. Compressing Valve Spring 2. Remove spark plug, rocker arm and push rod on cylinders) to be serviced. 3. Apply compressed air to spark plug hole to hold valves in place. NOTE: A tool to apply air to cylinder is available thru local jobbers or may be hand-made. To make this tool, chisel spark plug as shown in Figure 10, then drive porcelain out of plug by tapping center electrode against a hard block. Using a 3/8" (9.5mm) pipe tap, cut threads in remaining portion of spark plug and assemble as shown in Figure 10. (Later engines use tapered plug.) 4. Compress valve spring with Tool J-5892 and remove valve keys, valve(Figure 11) spring cap, spring shield and valve spring. 5. Remove valve stem oil seal. 174 To replace, set valve spring, valve shield and valve cap in 7. Install valve keys and release compressor tool. Be sure that keys seat properly in upper groove of valve stem. place. (Close, coiled end of spring is installed against cylinder head.) Compress spring with Tool J-5892 and install oil seal in lower groove of stem, making sure that NOTE: Grease may be used to hold keys in place while seal is flat and not twisted. releasing compressor tooL 8. Install spark plug, using a new gasket, and torque to NOTE: A light coat of oil on seal will help prevent specifications. twisiting when compressor tool is released. 9. Install and adjust valve mechanism as outlined. MERCRUISER ENGINE - 5A-7 977 R1 CYLINDER HEAD ASSEMBLIES CAUTION: Gasket surfaces on both head and block must be clean of any foreign matter and free of nicks and/or deep scratches. Cylinder bolt threads in block, and threads on cylinder head bolt must be cleaned. Dirt will affect bolt torque. DO NOT use gasket sealer on composition steel asbestos gaskets. 1. Place new gasket in position over dowel pins. CAUTION: DO NOT use steel automotive type cylinder head gaskets. Use only MerCap replacement parts. 2. Carefully guide cylinder head into place over dowel pins and gasket. 3. Coat threads of cylinder head bolts with Perfect Seal Figure 1. Cylinder Head Torque Sequence (C-92-34227) and install finger-tight. 4. Tighten cylinder head bolts a little at a time in sequence shown on torque sequence chart (Figure 1) until specified torque is reached. REMOVAL NOTE: Be sure to torque cylinder head on all 6-cylinder engines while performing 20-hour checkup. Failure to 1. Drain water from cylinder block and manifold. retorque could result in poor engine performance, blown 2. Disconnect fuel line support clamps and remove fuel line. cylinder head gaskets, burned valves, warped cylinder head 3. Remove exhaust manifold as outlined. or all four. 4. Disconnect cooling hoses water distribution housing. 5. Disconnect wire from temperature sending unit (located in water distribution housing) and remove water distribution housing from cylinder head. 5. Install valve mechanism and rocker arm cover as outlined. 6. Disconnect wires from coil and remove coil. 6. Install spark plugs and spark plug leads to proper plugs. 7. Remove circuit breaker bracket and lifting eye. 7. Install lifting eye and circuit breaker bracket. 8. Disconnect spark plug leads from spark plugs and remove 8. Install coil and coil leads. all spark plugs from cylinder head. 9. Install water distribution housing to cylinder head and 9. Remove rocker arm cover and valve mechanism as out-connect temperature sending unit lead. lined. 10. Connect cooling hoses to water distribution housing. 10. Remove cylinder head bolts, cylinder head and gasket. 11. Install exhaust manifold as outlined. Handle cylinder head carefully to prevent damage. 12. Install fuel line and fuel line support clamps. CYLINDER HEAD ASSEMBLIES and VALVE CONDITIONING DISASSEMBLY 1. Remove cylinder head as outlined. 2. Compress the valve springs with Tool J-8062 (Figure 2) and remove valve keys. Release compressor tool and remove spring caps, spring shields and valve springs. Remove oil seals from valves. 3. Remove valves from cylinder head and place them in a rack in their proper sequence for later assembly in their original positions. 5A-8 - MERCRUISER ENGINE CLEANING 1. Qean all carbon from combustion chambers and valve ports with Tool J-8089. (Figure 3) 2. Thoroughly clean valve guides with Tool J-8101. (Figure 4) 3. Clean all sludge from push rods, rocker arms and push rod guides. 4. Clean valve stems and valve heads on a buffing wheel. 5. Qean cylinder head gasket mating surface. Figure 2. Compressing Valve Spring Figure 3. Cleaning Combustion Chambers 01593 Figure 4. Cleaning Valve Guides INSPECTION 1. Inspect cylinder head gasket surface for flatness. Max. is .003" (.076mm) warpage in any 6" (15cm) area or .007" (.178mm) overall. If not within specifications, resurface or replace cylinder head. 2. Inspect cylinder head for cracks in exhaust ports, combustion chambers or external cracks to water chamber. 977 R1 3. Inspect valves for burned heads, cracked faces or damaged stems. NOTE: Excessive valve stem to bore clearance will cause excessive oil consumption and may cause valve breakage. Insufficient clearance will result in noisy and sticky valves and disturb smooth engine operation. 4. Measure valve stem clearance as follows: Clamp a dial indicator on one side of cylinder head rocker arm cover gasket rail, locating indicator so that movement of valve stem from side-to-side (crosswise to head) will cause a direct movement of indicator stem. Indicator stem must contact side of valve stem just above valve guide. With valve head dropped about 1/16" (1.6mm) off valve seat, move stem of valve from side-to-side, using light pressure to obtain a clearance reading. If clearance exceeds specifications, it will be necessary to ream valve guides for oversize valves as outlined. 5. Check valve spring tension with Tool J-8056 spring tester. (Figure 5) NOTE: Compress springs to specified height and check against specification chart. Replace if not within 10 lbs. of specified load (without dampers). 6. Inspect rocker arm studs for wear or damage. Torque Wrench Figure 5. Checking Valve Spring Tension ROCKER ARM STUDS Rocker arm studs with damaged threads or with loose fit in cylinder heads should be replaced with new studs available in .003" and .013" (,076mm and .330mm) oversize. Studs may be installed after reaming holes as follows: MERCRUISER ENGINE - 5A-9 1. Drain water from cylinder block. 2. Remove old stud by placing Tool J-5802-1 over stud, installing nut and flat washer and removing stud by turning nut. (Figure 6) 3. Ream hole for oversize stud with Tool J-5715 for .003" (,076mm) oversize or Tool J-6036 for .013" (,33mm) oversize. (Figure 7) CAUTION: Do not attempt to install an oversize stud without reaming stud hole. 4. Coat press-fit area of stud with Perfect Seal (C-92-34227). Install new stud, using Tool J-6880 as a guide. Gauge should bottom on head. (Figure 8) 01597 Figure 6. Removing Figure 7. Reaming Rocker Arm Stud Rocker Arm Stud Bore VALVE GUIDE BORES Valves with oversize stems are available (see specifications). To ream valve guide bores for .015" (.381mm) oversize valves, use Tool J-5830-2 and for standard, use Tool J-4S22. (Figure 9) Figure 8. Installing Figure 9. Reaming Rocker Arm Stud Valve Guide VALVE SEATS 1. Valves must seat perfect for the engine to deliver the power and performance built into it. 5A-10 - MERCRUISER ENGINE 2. Good contact between each valve and its seat in head is a must to ensure that heat in valve head will be properly carried away (cooled). 3. Recommendations of equipment manufacturer for reseat ing valve seats should be carefully followed to attai. proper results. Regardless of what type of equipment is used, however, it is essential that valve guide bores be free from carbon or dirt. 4. After grinding valve seat, check seat for out-of-round. (Figure 10) (Max. is .002" [.05mm] out-of-round with total indicator reading.) Figure 10. Measuring Valve Seat Concentricity VALVES Pitted valves can be refaced to proper angle (Figure 11) thus ensuring correct relation between head and stem on valve refacing mechanism. Valve stems, which show excessive wear or valves that are warped excessively, should be replaced. When a valve head (warped excessively) is refaced, a knife edge will be ground on part or all of valve head due to amount of metal that must be removed to completely reface. Knife edges lead to breakage, burning or pre-ignition from heat localizing on this knife edge. If edge of valve head is less than 1/32" (.8mm) thickness after grinding, replace valve. Recommendations of equipment manufacturer for refacing valves should be carefully followed to obtain best results. NOTE: Only extreme end of valve stem is hardened to resist wear. Do not grind end of stem excessively. 1. After cleaning valve face and cylinder head valve seat of grinding particles, make pencil marks about (6.4mm) apart across valve face, place valve in cylinder head and give valve /4-turn in each direction while exerting firm pressure on head of valve. 2. Remove valve and check face carefully. If all pencil marks have not been removed at point of contact with valve seat, it will be necessary to repeat refacing operation and again recheck for proper seating. 3. Grind and check remaining valves in same manner. 174 Exhaust Valves - All Engines Figure 11. Relation of Valve and Seat Angles REASSEMBLY 1. Insert valve in proper port. 2. Assemble valve spring and related parts as follows: a. Set valve spring, valve shield and valve cap in place. (Figure 12) Close, coiled end of spring is installed against cylinder head. b. Compress spring with Tool J-8062. c. Install oil seal in lower groove of stem, making sure that seal is flat and not twisted. Figure 12. Valve Spring Installation NOTE: A light coat of oil on seal will help prevent twisting when compressor tool is released. OIL REMOVAL 1. Disconnect battery (if connected). 2. Drain engine oil. 3. Remove starter motor. 4. Remove oil pan screws, oil pan, side and end gaskets. INSTALLATION 1. Thoroughly clean all gasket sealing surfaces. d. Install valve locks and release compressor tool, making sure that locks seat properly in upper groove of valve stem. NOTE: Grease may be used to hold locks in place while releasing compressor tool. 3. Install remaining valves. Figure 13. Vacuum Cup 4. Check each valve stem oil seal by placing a vacuum cup or similar device over end of valve stem and against cap. Operate vacuum cup and make sure that no air leaks past seal. A vacuum cup can be made from a small syringe and a high voltage shield. (Figure 13) 5. Check installed height of valve springs with scale. (Figure 14) Measure from top of spring seat to top of valve spring shield. (Figure 14) If this exceeds specified height, install a valve spring seat shim approximately 1/16" (1.6mm) thick. At no time should spring be shimmed to give an installed height under minimum specified. Figure 14. Checking Valve Spring Installed Height PAN 2. Install rear gasket (rubber) in rear main bearing cap. 3. Install front gasket (rubber) on timing gear cover. 4. Install side gaskets on cylinder block, using grease as a retainer. Locate side gasket tabs into notches of front seal. 5. Install oil pan. 6. Install starter motor. 7. Fill crankcase with oil. 8. Connect battery . 977 R1 MERCRUISER ENGINE - 5A-11 OIL Oil pump consists of 2 gears and a pressure regulator valve enclosed in a 2-piece housing. Oil pump is driven by distributor shaft which is driven by a helical gear on camshaft. A baffle is incorporated on pickup screen to eliminate pressure loss. Use Figure 15 for reference. REMOVAL 1. Remove oil pan as outlined. 2. Remove flange mounting bolts and pickup pipe bolt, then remove pump and screen as an assembly. DISASSEMBLY NOTE: DO NOT remove pickup screen and pipe assembly unless replacement is necessary. Loss of press fit condition could result in air leak and loss of oil pressure. 1. Remove pump cover attaching screws, pump cover and pump cover gasket. NOTE: Mark gear teeth so they may be reassembled with same teeth indexing. 2. Remove idler gear and drive gear and shaft from pump body. 3. Remove pressure regulator valve retaining pin, pressure regulator, spring and valve. 4. If pickup screen and pipe assembly need replacing, mount pump in a soft-jawed vise and extract pipe from pump. CAUTION: Do not disturb pickup screen on pipe which is serviced as an assembly. CLEANING and INSPECTION 1. Wash all parts in cleaning solvent and dry with compressed air. 2. Inspect pump body and cover for cracks or excessive wear. 3. Inspect pump gears for damage or excessive wear. 4. Check drive gear shaft for looseness in pump body. 5. Inspect inside of pump cover for wear that would permit oil to leak past ends of gears. 6. Inspect pickup screen and pipe assembly for damage to screen, pipe or relief grommet. 7. Check pressure regulator valve for fit. NOTE: Pump gears and body are not serviced separately. If pump gears or body are damaged or worn, replace entire oil pump assembly. REASSEMBLY If pickup screen and pipe assembly was removed, replace with a new part. Loss of press fit condition could result in air leak and loss of oil pressure. Mount pump in soft-jawed vise and apply Perfect Seal No. 4 (C-92-34227) to end of pipe with Tool J-8369. Tap pipe in place with plastic hammer. PUMP CAUTION: Be careful of twisting, shearing or collapsing pipe while installing in pump. Pickup screen must be parallel to bottom of oil pan when oil pump is installed. 2. Install pressure regulator valve spring and retaining pin. 3. Install drive gear and shaft in pump body. 4. Install idler gear in pump body with smooth side of gear toward pump cover opening, aligning teeth marked in disassembly. 5. Install pump cover with new gasket and torque attaching screws to specifications. 6. Turn drive shaft by hand to check for smooth operation. 01628 Figure 15. Oil Pump 1 - Pressure Regulator Valve 6 - Cover Gasket 2 - Pressure Regulator Spring 7 - Idler Gear 3 - Retaining Pin 8 - Drive Gear and Shaft 4 - Screws 9 - Pump Body 5 - Pump Cover 10 - Pickup Screen and Pipe INSTALLATION 1. Align oil pump drive shafts to match with distributor tang, then install oil pump to block, positioning flange over distributor lower bushing. Use no gasket. NOTE: Oil pump should slide easily into place. If not, remove and reposition slot to align with distributor tang. 2. Install oil pump bolts and tighten securely. 3. Install oil pan as outlined. 5A-12 - MERCRUISER ENGINE CRANKSHAFT PULLEY REMOVAL 1. Support front of engine (if in boat) with overhead hoist. 2. Remove front mounting bracket and drive belt. Remove crankshaft pulley from pulley hub. 3. Install puller Tool J-6978 to pulley hub with two 3/8 x 2" and one 5/16 x 2" bolts and remove hub. (Figure 1) Remove puller tool. INSTALLATION 1. Coat oil seal lip with engine oil, position hub over crankshaft and key and start hub into position with a TORSIONAL REMOVAL 1. Support front of engine (if in boat) with overhead hoist. 2. Remove front mounting bracket and drive belt. (Remove retaining bolt, if so equipped.) 3. Install Tool J-6978 to balancer and turn puller screw to remove damper. (Figure 3) Remove tool from damper. CAUTION: Inertia weight section of torsional damper is assembled to hub with rubber type material. Installation procedures (with proper tool) must be followed or movement of inertia weight section on hub will upset tuning of torsional damper. INSTALLATION 1. Coat front cover oil seal lip with engine oil. 2. Attach damper installer Tool J-8792 to damper as shown in Figure 4. mallet. Using Tool J-5590, strike hub until it bottoms against crankshaft gear. NOTE: Crankshaft extends slightly thru hub, and a tool is necessary to drive hub completely into bottomed position. 2. Install pulley onto hub. NOTE: There are two 3/8" (9.5mm) holes and one 5/16" (7.9mm) hole that must be matched on hub in order to properly position timing mark. (Figure 2) 3. Install drive belt and adjust tension. 4. Install front mounting bracket. Figure 2. Install Pulley To Hub DAMPER Figure 3. Removing Harmonic Balancer 977 R1 MERCRUISER ENGINE - 5A-13 Position damper on crankshaft and drive into position until it bottoms against crankshaft gear. Remove installation tool. Install drive belt and adjust tension. Install front mounting bracket. Figure 4. Installing Harmonic Balancer CRANKCASE FRONT COVER REMOVAL 1. Remove oil pan as outlined. 2. Remove crankshaft pulley and hub or damper as outlined. 3. Remove crankshaft front cover attaching screws, cover and gasket. INSTALLATION 1. Clean gasket surfaces on block and crankcase front cover. 06056 2. Install centering Tool J-23042 in crankcase front cover Figure 5. Centering Tool (J-23042) In Cover seal. (Figure 5) 3. Coat gasket with gasket sealer and place in position on cover, then install crankcase front cover to block and torque to specifications. not damage seal and to position seal to seal evenly around 4. Remove centering tool. clamper or hub surface. NOTE: Use only centering tool to align crankcase front 5. Install crankshaft hub and/or damper as outlined. cover so that crankshaft hub or damper installation will 6. Install oil pan as outlined. OIL SEAL (FRONT COVER) REPLACEMENT CAUTION: Support cover at sealing area. Tool J-971 may be used as support. With Cover Removed Without Cover Removed 1. With cover removed, pry old seal out of cover from front 1. Writh crankshaft pulley and hub or damper removed, pr\ with large screwdriver. old seal out of cover from front with large screwdriver, being careful not do damage seal surface on crankshaft. 2. Install new seal so that open end of seal is toward inside of 2. Install new seal so that open end of seal is toward inside of cover and drive seal into position with Tool J-23042. cover and drive seal into position with Tool J-23042. (Figure 6) (Figure 7) 5A-14 - MERCRUISER ENGINE 174 3.4.5.6. Figure 6. Installing Oil Seal (Cover Removed) Figure 7. Installing Oil Seal (Cover Installed) FLYWHEEL and COUPLER REMOVAL 1. Remove engine from boat. 2. Remove bell housing. 3. Remove coupler by removing retaining nuts and washers. 4. Remove flywheel. INSPECTION Engine Coupling 1. Failure of engine coupling assembly spline and/or universal splined shaft caused by insufficient lubrication at time of installation. On initial installation and whenever a stern drive unit is removed, lubricate engine coupling splines with Multipurpose Lubricant (C-92-63250). The spline mating surfaces will wear very rapidly if installed dry. NOTE: In applications where trolling constitutes most of the operation time. Universal Joint Lubricant (C-92-74058A1) will provide more satisfactory service. Figure 8. Flywheel Position on Crankshaft Flange 2. Hub bond, which shears or pulls loose from hub center, indicates engine drive misalignment. Align engine with correct alignment tool. dowel hole in crankshaft flange and set flywheel in place Flywheel on studs. (Figure 8) 2. Place drive coupling on studs and install washers and lock Check flywheel ring gear for worn or missing teeth. nuts. Torque nuts to specifications with Torque Wrench and Adaptor (C-91-54638). INSTALLATION 3. Install bell housing. 1. Install flywheel. Line up dowel hole in flywheel with 4. Lubricate coupler splines and install engine in boat. 977R1 MERCRUISER ENGINE -5A-15 OIL SEAL (REAR MAIN) REPLACEMENT 3. Lubricate lip of new seal with engine oil. Keep oil of. parting line surface, as this is treated with glue. Insert seal Rear main bearing oil seal can be replaced (both halves) in cap and roll seal into place with finger and thumb, using without removing crankshaft. light pressure so seal tangs at parting line do not cut bead on back of seal. NOTE: Always replace upper and lower seal as a unit. 4. To remove upper half of seal, use small hammer and tap Install with lip facing toward front of engine. Where seal brass pin punch on one end of seal until it protrudes far has 2 lips, install lip with helix toward front of engine. enough to be removed with pliers. (Figure 9) 1. With oil pan removed, remove rear main bearing cap. NOTE: Always wipe crankshaft surface clean before 2. Remove oil seal from rear main bearing cap by prying from installing new seal. bottom with small screwdriver. Apply Sealant to Shaded Areas Only 01711 Figure 10. Sealing Bearing Cap and Block 5. Lubricate lip of new seal with engine oil. Keep oil off parting line surface. Gradually push with a hammer handle (while turning crankshaft) until seal is rolled into place (similar to installing a main bearing). Be careful that seal tangs at parting line do not cut bead on back of seal. Use sealer at parting line on rear main bearing cap half of seal. 6. Apply Perfect Seal No. 4 (C-92-34227) to cylinder block in seal area. (Figure 10) 7. Install rear main bearing cap (with new seal) and torque to specifications. 8. Install oil pan as outlined. 5C-16 - MERCRUISER ENGINE 977 R1 MAI N BEARINGS 1. Main bearings are precision insert type and do not utilize shim for adjustment. If clearances are found to be excessive, a new bearing (both upper and lower halves) will be required. Bearings are available in standard size and .001", .002", .010". and .020" undersize. (1" = 25.4mm) 2. Selective fitting of both rod and main bearing inserts is necessary in production to obtain close tolerances. For example, one half of a standard insert with one half of a .001" undersize insert may be found, which will decrease clearance .0005" from using a full standard bearing. 3. When a production crankshaft cannot be precision fitted by this method, it then is ground .009" undersize on main journals only. A .009" undersize bearing and .010" undersize bearing may be used for precision fitting in same manner as previously described. Any engine, fitted with a .009" undersize crankshaft, will be identified by following markings. • ".009 " will be stamped on crankshaft counterweight forward of center main journal. • No. "9" will be stamped on block at left front oil pan rail. INSPECTION In general (except No. 1 bearing), lower half of bearing shows greater wear and most distress from fatigue. If. upon inspection, lower half is acceptable, it can be assumed that upper half also is satisfactory. If lower half shows evidence of wear or damage, replace both upper and lower halves. Never replace one half without replacing other half. Typical bearing failures are shown in Figure 1, following. Sections SCRATCHED LACK OF OIL intoIMPROPER SEATING BY DIRT Be3ring from Entire Surface TAPERED JOURNAL RADIUS RIDE FATIGUE FAILURE Figure 1. Typical Bearing Failure CHECKING CLEARANCE To obtain most accurate results, use Plastigage (or its equivalent), a wax-like plastic material which will compress evenly between bearing and journal surfaces without damaging either surface. With engine upside down, crankshaft will rest on upper bearings, and total clearance can be measured between lower bearing and journal. NOTE: To assure proper seating of crankshaft, torque all bearing cap bolts as specified. In addition, before checking fit of bearings, wipe surface of crankshaft journal and face and back of bearing clean of oil. 1. With oil pan and oil pump removed, and starting with rear main bearing, remove bearing cap and wipe oil from journal and bearing cap. 2. Place piece of gauging plastic the full width of bearing (parallel to crankshaft) on journal. (Figure 2) ^ Figure 2. Gauging Plastic on Journal MERCRUISER ENGINE - 5A-17 CONNECTING ROD BEARINGS CAUTION: Do not rotate crankshaft while the gauging plastic is between bearing and journal. 3. Install bearing cap and evenly torque retaining bolts to specifications. 4. Remove bearing cap. Flattened gauging plastic will be found adhering to either bearing shell or journal. 5. A graduated scale (correlated in thousandths of an inch) exists on edge of gauging plastic envelope. Without removing gauging plastic, measure its compressed width (at widest point) with graduations on gauging plastic envelope. (Figure 3) NOTE: Normally, main bearing journals wear evenly and are not out-of-round. However, if a bearing is being fitted to an out-of-round journal (.001" [,025mm] max.), be sure to fit to maximum diameter of journal. If bearing is fitted to minimum diameter, and journal is out-of-round .001", interference between bearing and journal will result in rapid bearing failure. If flattened gauging plastic tapers toward middle or ends, there is a difference in clearance indicating taper, low spot or other irregularity of bearing or journal. Be sure to measure journal with a micrometer if flattened gauging plastic indicates more than .001" difference. 01633 Connecting rod bearings are precision insert tvpe and do not utilize shims for adjustment. DO NOT FILE RODS OR ROD CAPS. If clearances are found to be excessive, a new bearing will be required. Bearings are available in standard size and .001" and .002" undersize for use with new and used standard size crankshaft and in .010" and .020" undersize for use with reconditioned crankshafts. (1" = 25.4mm) INSPECTION and REPLACEMENT 1. With oil pan and oil pump removed, remove connecting rod cap and bearing. 5C-18 - MERCRUISER ENGINE 6. If bearing clearance is within specifications, bearing insert is satisfactory. If clearance is not within specifications, replace insert. Always replace both upper and lower insert as a unit. 7. A standard .001" (,025mm) or .002" (,051mm) undersize bearing may produce proper clearance. If not, regrind crankshaft journal for use with next undersize bearing. 8. Proceed to next bearing. After all bearings have been checked, rotate crankshaft so that no excessive drag exists. 01653 9. Measure crankshaft end play (see specifications) by forcing crankshaft to extreme front position. Measure at front end of rear main bearing with feeler gauge. (Figure 4) 10. Install new rear main bearing oil seal in cylinder block and main bearing cap. MAIN BEARING REPLACEMENT 1. Remove and inspect crankshaft. 2. Remove main bearings from cylinder block and main bearing caps. 3. Coat bearing surfaces of new, correct-size, main bearings with oil and install in cylinder block and main bearing caps. Check clearance outlined. 4. Install crankshaft. 2. Inspect bearing for evidence of wear or damage. (Defective bearings should not be installed.) Typical bearing failures are shown in Figure 1, preceding. 3. Wipe bearings and crankpin clean of oil. 4. Measure crankpin for out-of-round or taper with a micrometer. If not within specifications, replace or recondition crankshaft. If within specifications and new bearing is to be installed, measure maximum diameter of crankpin to determine new bearing size required. 5. If within specifications, measure new or used bearing clearances with Plastigage or equivalent. 977 R1 NOTE: If bearing is being fitted to out-of-round crankpin, be sure to fit maximum diameter of crankpin. If bearing is fitted to minimum diameter, and crankpin is out-of-round .001", interference between bearing and crankpin will result in rapid bearing failure. a. Place a piece of gauging plastic the full width of crankpin (parallel to crankshaft). (Figure 5) b. Install bearing connecting rod and cap. c. Install bearing cap and torque nuts evenly to specifications. CAUTION: Do not turn crankshaft with gauging plastic installed. d. Remove bearing cap and, using scale on gauging plastic envelope, measure gauging plastic width at widest point. (Figure 6) 6. If clearance exceeds specifications, select a new, correct- size bearing and remeasure clearance. 7. Coat bearing surface with oil, install rod cap and torque nuts to specifications. 8. When all connecting rod bearings have been installed, tap each rod lightly (parallel to crankpin) to be sure they have clearance. CONNECTING ROD and REMOVAL 1. With oil pan, oil pump and cylinder head removed, use a ridge reamer to remove any ridge and/or deposits from upper end of cylinder bore. NOTE: Before ridge and/or deposits are removed, turn crankshaft until piston is at bottom of stroke and place a cloth on top of piston to collect cuttings. After ridge 9. Measure all connecting rod side clearances (see specifications) between connecting rod and side of crankpin. (Figure 7) Figure 6. Measuring Gauging Plastic 01636 Figure 7. Measuring Connecting Rod Side Clearance PISTON ASSEMBLIES and/or deposits are removed, turn crankshaft until piston is at top of stroke and remove cloth and cuttings. 2. Inspect connecting rods and connecting rod caps for cylinder identification. If necessary, mark them. 3. Remove connecting rod cap and install Tool J-6305 (11/32") on bolts. (Figure 1) Push connecting rod and piston assembly out of top of cylinder block. NOTE: It will be necessary to turn crankshaft slightly to disconnect some connecting rod and piston assemblies. 977 R1 MERCRUISER ENGINE - 5A-19 DISASSEMBLY (METHOD "1") If bosses on pistons do not allow piston support Tool J-9510-1 to seat squarely on piston for press operations, modifications to tool are necessary. To allow adequate clearance for these bosses, turn or grind upper portion of tool to dimensions shown in Figure 2. Installation of 181 cubic inch pistons may require additional grinding of support tool beyond dimensions shown in Figure 2. Modification of tool, as described, does not affect tool application on other pistons. 1. Remove connecting rod 01646 bearings from connecting Figure 1. Guide Tool rods and caps. J-6305 Installed NOTE: If connecting rod bearings are being reused, place in a rack for reinstallation in original rod and cap. 2. Use piston ring expander to expand rings and remove from pistons. 3. Place connecting rod and piston assembly in arbor press with piston on support Tool J-9510-1 and 05041 press piston pin out of con- Figure 2. Piston Support necting rod and piston. Tool J-9510-1 (Figure 3) Figure 3. Removing Piston Pin 01637 5A-20 - MERCRUISER ENGINE a - Arched Base c - Adjustable Installer e - Piston Pin b - Rod Support d - Piston Pin Guide Remover Figure 4. Tool (J-24086-100) Parts Identification DISASSEMBLY (METHOD "2") 1. Use Tool Kit (J-24086-100), shown in Figure 4. 2. Position connecting rod onto tool rod support with rod support inserted between connecting rod end and piston. Align piston pin with hole located in top of arched base. (Figure 5) 3. Insert pin remover thru hole (located in top of arched base) and into piston pin hole. Press on pin remover to remove piston pin. (Figure 5) a - Piston Pin Remover c - Piston e - Rod Support b - Arched Base d - Connecting Rod Figure 5. Removing Piston Pin 977 R1 CLEANING and INSPECTION Connecting Rods 1. Wash connecting rods in cleaning solvent and dry with compressed air. 2. Check for twisted or bent rods and inspect for nicks or cracks. Replace damaged connecting rods. Pistons 1. Clean varnish from piston skirts and pins with cleaning solvent. DO NOT WIRE BRUSH ANY PART OF PISTON. Clean ring grooves with groove cleaner and make sure oil ring holes and slots are clean. 2. Inspect piston for cracked ring lands, skirts or pin bosses, wavy worn ring lands, scuffed or damaged skirts and eroded areas at top of piston. Replace pistons which are damaged or show signs of excessive wear. 3. Inspect grooves for nicks or burrs which might cause rings to hang up. 4. Measure piston skirt (across centerline of piston pin) and check clearance as outlined under "Piston Selection". Piston Pins 1. Piston and piston pin are a matched set and not serviced separately. Remover ond Installer Piston Pin Connecting Rod Pilot Bearing Tong Slots Spring Support 05033 Figure 6. Piston Pin Installation 977 R1 Figure 7. Connecting Rod and Oven 2. Pin bores and piston pins must be free of varnish or scuffing. Measure piston pin with a micrometer and piston pin bore with a dial bore gauge or inside micrometer. If clearance is in excess of .001" (.025mm) wear limit, replace piston and piston pin assembly. REASSEMBLY (METHOD "1") CAUTION: DO NOT oil piston pin or connecting rod (Figure 6) before rod end Is to be heated for Installation. Notch 04991 04989 Model 153 Cu. In. Models 181 and 250 Cu. In. Figure 8. Connecting Rod and Piston Assembly MERCRUISER ENGINE - 5A-21 1. Heat piston pin end of connecting rod. NOTE: An oven is recommended to heat piston pin end of connecting rod prior to piston installation. (Figure 7) 2. Place support Tool J-9510-1 with spring and pilot in place on arbor press. 3. Position piston on connecting rod with notched side of piston (Figure 8) and connecting rod tangs aligned. 4. Place piston on support, indexing pilot through piston and rod. 5. Place installer (Figure 6) on piston pin, start piston pin and press on installer until pilot bottoms in support. 6. Remove installer from connecting rod and piston assembly and check piston for freedom of movement on piston pin. 7. Allow connecting rod and piston assembly to cool, then oil piston pin. REASSEMBLY (METHOD "2") 1. Lubricate piston pin, piston pin hole in piston and hole in rod end with a light coat of engine oil. 2. Position rod onto rod support and piston onto rod end. Insert piston pin guide thru bottom piston pin hole and into connecting rod. Place piston pin thru top side of piston. (Figure 9) 3. Adjust adjustable installer to setting specified on chart (which, came with tool) for particular piston installation. Lock adjustable installer with jam nut. 4. Insert adjustable installer thru hole (located on top of arched base) and into piston pin hole. Carefully press on adjustable installer until installer bottoms-out on arched base to install piston pin. a - Jam Nut d - Piston f - Piston Pin b - Adjustable Installer e - Connecting Rod g - Rod Support c - Arched Base ^^ Figure 9. Installing Piston Pin 10073 PISTON RINGS All compression rings are marked on upper side of ring. When installing compression rings, make sure marked side is toward top of piston. Top ring is treated with molybdenum for maximum life. Oil control rings are 3-piece type, consisting of 2 segments (rails) and a spacer. Figure 10. Measuring Ring Gap 5C-22 - MERCRUISER ENGINE Figure 11. Ring Gap Location 1. Select rings comparable in size to piston being used. 2. Slip compression ring in cylinder bore, then press ring down into cylinder bore about '/i" (6.4mm) (above ring — travel). Be sure that ring is square with cylinder wall. 3. Measure space or gap between ends of ring with a feeler gauge. (Figure 10) 4. If gap between ends of ring is below specifications, remove ring and try another for fit. 5. Fit each compression ring to cylinder in which it will be used. 977 R1 6. Clean and inspect pistons, as previously outlined, if not already completed. 7. Slip outer surface of top and second compression ring into respective piston ring groove and roll ring entirely around groove (Figure 12) to make sure that ring is free. If binding occurs at any point, determine cause and. if caused by ring groove, remove by dressing with a fine cut file. If binding is caused by a distorted ring, use a new ring. 8. Install piston rings as shown in Figure 11. Ring installation tools are: Model Engine Displacement (Cu. In.) Tool No. 153,250 181 J-8021 (3-7/8") J-8032 (4") Figure 12. Checking Ring in Groove a. Install oil ring spacer in groove and (except on 250) insert anti-rotation tang in oil hole. replaced, then replace camshaft also, since replacement con- b. Hold spacer ends butted and install lower steel oil ring necting rods are not ground for clearance, and replacement rail with gap properly located. (Figure 11) camshafts have a smaller fuel pump lobe. c. Install upper steel oil ring rail with gap properly located. 4. Install each connecting rod and piston assembly in respecd. Flex oil ring assembly to make sure that ring is free. If tive bore. Pistons must have piston notch facing front of binding occurs at any point, determine cause and, if engine. Use Tool J-8307 to compress rings. (Figure 13) caused by ring groove, remove by dressing groove with Guide connecting rod into place on crankshaft journal a fine cut file. If binding is caused by a distorted ring, with Tool J-5239. Use light blows with hammer handle to use a new ring. install piston into bore. Hold ring compressor firmly e. Install second compression ring expander, then ring against cylinder block until all piston rings have entered with gaps properly located. cylinder bore. f. Install top compression ring with gap in correct 5. Remove guide tool. location. 6. Install bearing caps and torque nuts to specification. 9. Proper clearance of piston ring in piston ring groove is necessary for proper ring action and to reduce wear. NOTE: If bearing replacement is required, refer to "Connect- Therefore, when fitting new rings, measure clearances ing Rod Bearings", preceding. between ring surfaces and groove. (See "Specifications" Section 8.) NOTE: Be sure to install new pistons in same cylinders for which they were fitted and used pistons in same cylinders from which they were removed. Each connecting rod and bearing INSTALLATION cap should be marked, beginning at front of engine. NOTE: Cylinder bores must be clean before piston installation. Clean with hot water and detergent wash or with a light honing, as necessary. After cleaning, swab bores several times with light engine oil and a clean cloth. 1. Lubricate connecting rod bearings and install in rods and rod caps. 2. Lightly coat pistons, rings and cylinder walls with light engine oil. 3. With bearing caps removed, install Tool J-6305 (11/32") on connecting rod bolts. CAUTION: Be sure that ring gaps are properly posi tioned as previously outlined. NOTE: Early Model "181", No. 2 connecting rods have a ground recess on camshaft side to provide clearance for fuel pump lobe on camshaft. Be sure that No. 2 connecting rod is installed in same location and position. If connecting rod is Figure 13. Installing Connecting Rod and Piston Assemblies 977 R1 MERCRUISER ENGINE - 5A-23 CRANKSHAFT Crankshaft can be removed while engine is disassembled for overhaul or without complete disassembly. REMOVAL 1. Remove flywheel housing, coupler and flywheel. 2. Remove starter motor. 3. Remove spark plugs. 4. Remove crankshaft pulley or torsional damper. 5. Remove oil pan and oil pump. 6. Remove crankcase front cover. 7. Check connecting rod caps for cylinder number identification. If necessary, mark caps. 8. Remove connecting rod caps and push pistons to top of bores. 9. Remove main bearing caps and lift crankshaft out of cylinder block. 10. Remove rear main bearing oil seal and main bearings from cylinder block and main bearing caps. CLEANING and INSPECTION 1. Wash crankshaft in solvent and dry with compressed air. 2. Measure dimensions of main bearing journals and crank- pins with a micrometer for out-of-round, taper or under- size (see "Specifications" Section 8). 3. Check crankshaft for run-out by supporting at front and rear main bearing journals in "V " blocks and check at front and rear intermediate journals with a dial indicator (see "Specifications"). 4. Replace or recondition crankshaft if not within specifications. INSTALLATION 1. Install crankshaft as follows: a. Install rear main bearing oil seal in cylinder block and rear main bearing cap grooves. Install with lip of seal toward front of engine. b. Lubricate lip of seal with engine oil. Keep oil off parting line surface. c. Install main bearings in cylinder block and main bearing caps, then lubricate bearing surface with engine oil. d. Install crankshaft, being careful not to damage bearing surfaces. e. Apply a thin coat of brush-on type oil sealing compound to block mating surface and corresponding surface of cap only. Do not allow sealer on crankshaft or seal lip. f. Install main bearing caps with arrows pointing toward front of engine. g. Torque all except rear main bearing cap bolts to 10-12 ft. lbs. (1.38 to 1.66mkg). Torque rear main bearing cap bolts to specifications, then tap end of crankshaft, first from rear then forward, with a lead hammer. This will line up rear main bearing and crankshaft thrust surfaces. Retorque all main bearing cap bolts to specifications. h. Measure crankshaft end play with a feeler gauge. Force crankshaft forward and measure clearance between front of rear main bearing and crankshaft thrust surface. (Figure 1) 2. Install connecting rod and caps as outlined. 3. Install crankcase front cover as indicated. 4. Install oil pump and oil pan as outlined. 5. Install crankshaft pulley or torsional damper as indicated. 6. Install starter motor. 7. Install flywheel, coupler and flywheel housing as outlined. 8. Install spark plugs and torque to specifications. CAMSHAFT MEASURING LOBE LIFT NOTE: Procedure is similar to checking valve timing. If improper valve operation is indicated, measure lift of each push rod in consecutive order and record the readings. 1. Remove valve mechanism as outlined. 2. Position indicator with ball socket adaptor (Tool J-8520) on push rod. (Figure 2) 3. Rotate torsional damper slowly in direction of rotation until lifter is on lowest position of cam lobe. 4. Set dial indicator on zero, then rotate damper slowly, or attach an auxiliary starter switch and "bump" engine over, until push rod is in fully raised position. 5. Compare total lift recorded from dial indicator with "Specifications", Section 8. 6. Continue to rotate crankshaft until indicator reads zero. This will be a check on accuracy of original indicator reading. 7. If camshaft readings for all lobes are within specifications, remove dial indicator assembly. 8. Install and adjust valve mechanism as outlined. 5A-24 - MERCRUISER ENGINE REMOVAL 1. Remove valve lifters as outlined. 2. Remove crankcase front cover as outlined. 3. Remove fuel pump as outlined. 4. Align timing gear marks, then remove 2 camshaft thrust plate screws by working thru holes in camshaft gear. (Figure 3) 5. Pull camshaft and gear assembly out thru front of block. NOTE: Support camshaft carefully when removing to protect camshaft bearings. INSPECTION 1. Measure camshaft bearing journals with a micrometer for out-of-round condition. If journals exceed .001" (.025mm) out-of-round. replace camshaft. 977 R1 2. Check camshaft for alignment with "V " blocks and dial indicator (Figure 4) for exact amount that camshaft is out-of-true. If out more than .002" (.051mm) dial indicator reading, replace camshaft. 3. On in-line engines, inspect camshaft gear and thrust plate for wear or damage. Measure camshaft end play (.001" to .005" [.025mm to ,127mm ]). (Figure 5) 01689 Figure 4. Checking Camshaft Alignment Camshaft Thrust Plate Camshaft Gear Feeler Strip Figure 5. Measuring Camshaft End Play CAMSHAFT GEAR REPLACEMENT 1. If inspection (preceding) indicated that camshaft, gear or thrust plate should be replaced, remove gear from camshaft with camshaft gear remover Tool J-971. 2. Place camshaft thru gear remover, place end of remover on table of a press and press shaft out of gear. (Figure 6) CAUTION: Position thrust plate so that woodruff key in shaft does not damage plate when shaft is pressed out of gear. Also support hub of gear, or gear will be seriously damaged. 3. To assemble camshaft gear, thrust plate and gear spacer ring to camshaft, firmly support camshaft at back of front journal in arbor press. MERCRUISER ENGINE - 5A-25 4. Place gear spacer ring and thrust plate over end of shaft, and install woodruff key in shaft keyway. Press shaft gear onto shaft until it bottoms against gear spacer ring. End clearance of thrust plate should be .001" to .005" (.025mm to ,127mm). (Figure 5) Figure 6. Removing Camshaft Gear INSTALLATION 1. Install camshaft and gear assembly in engine block, being careful not to damage camshaft bearings or camshaft. Figure 7. Crankshaft Gear 2. Turn crankshaft and camshaft so that timing marks on gear teeth will line up. (Figure 7) Push camshaft thrust plate to block screws and torque to specifications. 3. Check camshaft and crankshaft gear run-out with a dial indicator. (Figure 8) Camshaft gear run-out should not 5A-26 - MERCRUISER ENGINE exceed .004" (.102mm) and crankshaft gear run-out should not exceed .003" (.076mm). 4. If gear run-out is excessive, remove gear and clean burrs from shaft, or gear must be replaced. 5. Check backlash between timing gear teeth with a dial indicator. (Figure 9) Backlash should not be less than .004", nor more than .006" (.152mm). 6. Install fuel pump as outlined. 7. Install crankcase front cover as described. 8. Install valve lifters as outlined. Figure 8. Checking Timing Gear Run-Out Figure 9. Checking Timing Gear Backlash CAMSHAFT BEARINGS REMOVAL With camshaft removed, inspect bearings for evidence of wear or damage. Replace defective bearings. Replace camshaft bearings while engine is disassembled for overhaul or without complete disassembly of the engine. To replace bearings without complete disassembly, remove camshaft and crankshaft, leaving cylinder heads attached and pistons in place. Before removing crankshaft, tape threads of connecting rod bolts to prevent damage to crankshaft. Fasten connecting rods against sides of engine so that rods will not hinder camshaft bearing replacement. 1. With camshaft and crankshaft removed, drive camshaft rear plug from cylinder block. NOTE: This procedure is based on removal of bearings nearest center of engine first. Thus, a minimum number of turns are necessary to remove all bearings. 2. Using Tool Set J-6098, with nut and thrust washer installed to end of threads, position pilot in front camshaft bearing and install puller screw thru pilot. 3. Install remover and installer tool with shoulder toward bearing, making sure a sufficient amount of threads are engaged. 4. Using 2 wrenches, hold puller screw while turning nut. When bearing has been pulled from bore, remove tool and bearing from puller screw. (Figure 10) 5. Remove remaining bearings (except front and rear) in same manner. Position pilot in rear camshaft bearing to remove rear intermediate bearing. 6. Assemble remover and installer tool on driver handle and remove front and rear camshaft bearings by driving toward center of cylinder block. (Figure 11) INSTALLATION Install front and rear camshaft bearings first. These bearings will act as guides for pilot and center remaining bearings being pulled into place. NOTE: Bearing O.D.'s for 6-cvUnder (Nos. 1 and 4) and 4-cylinder (No. 3) are 2.009"2.011" (51.03 to 51.08mm), and 6-cylinder (Nos. 2 and 3) and 4-cylinder (Nos. 1 and 2) are 1.999"-2.001" (50.77 to 50.83mm). 1. Assemble remover and installer tool on driver handle and install front and rear camshaft bearings by driving toward center of cylinder block. (Figure 11) CAUTION: Oil holes in bearings must line up with oil holes in cylinder block. Oil hole is on top side of bearing shell and cannot be seen during installation, so first align bearing shell oil hole with oil hole in bore and mark opposite side of bearing and block at bore to easily position oil hole during installation. NOTE: Front bearing must be driven approximately 1/8" (3.2mm) behind front of cylinder block to uncover oil hole to timing gear oil nozzle. Figure 11. Removing and Installing Camshaft Bearings 2. Using Tool Set J-6098, with nut and thrust washer installed to end of threads, position pilot in front camshaft bearing and install puller screw thru pilot. 3. Index camshaft bearing in bore, then install remover and installer tool on puller screw with shoulder toward bearings. 4. Using 2 wrenches, hold puller screw while turning nut. After bearing has been pulled into bore, remove tool from puller screw and check alignment of oil hole in camshaft bearing. (Figure 10) Figure 12. Removing Crankshaft Gear MERCRUISER ENGINE - 5A-27 5. Install remaining bearings in same manner. Position pilot in rear camshaft bearing to install rear intermediate bearing. 6. Install a new camshaft rear plug flush to 1/32" (,8mm) deep and parallel with rear surface of cylinder block.. Us Perfect Seal No. 4 (C-92-34227) on plug.' 06063 I Figure 13. Installing Crankshaft Gear 5A-28 - MERCRUISER ENGINE 977 R1 CYLINDER BLOCK CLEANING and INSPECTION 1. Wash cylinder block thoroughly in cleaning solvent and clean all gasket surfaces. 2. Remove oil gallery plugs and clean all oil passages. NOTE: Remove plugs with a sharp punch or drill and pry out. "A" = At Right Angle to Center- line of Engine "B" = Parallel to Centerline of Engine Taper = Difference between "A " Measurement at Top of Cylinder Bore and "A" Measurement at Bottom of Cylinder Bore Out-of-Round = Difference be 05042 tween "A" and "B" Figure 1. Cylinder Measurement 3. Clean and inspect water passages in cylinder block. 4. Inspect cylinder block for cracks in cylinder walls, water jacket valve lifter bores and main bearing webs. 5. Measure the cylinder walls for taper, out-of-round or excessive ridge at lop of ring travel (Figure 1) with dial indicator. (Figure 2) Set gauge so that thrust pin must be forced in about 54" (6.4mm) to enter gauge in cylinder bore. Center gauge in cylinder and turn dial to "0" . Carefully work gauge up-and-down cylinder to determine taper and turn gauge to different points around cylinder wall to determine out-of-round condition. If cylinders exceed specifications, honing and/or boring are necessary. (Figure 2) REPAIRS Cylinder Conditioning Condition of engine at time of repair is important. If inspection indicates that cylinder block is acceptable, except for out-of-round or tapered cylinders, condition the block by honing or boring. 977 R1 If cylinders have less than .005" (.127mm) taper or wear, condition them with a hone and fit with high limit, standard size piston. A cylinder bore of less than .005" wear or taper may not clean up entirely when fitted to a high limit piston. To clean up bore entirely, in such a case, rebore for an oversize piston. If more than .005" taper or wear, bore and hone to smallest oversize that permits complete resurfacing of all cylinders. When pistons are fitted (honing not necessary), clean (scrub) cylinder bores with detergent and hot water. After cleaning, swab cylinder bores several times with light engine oil with clean cloth, then wipe with clean, dry cloth. Cylinder Boring 1. Before using any type boring bar, file off top of cylinder block to remove dirt or burrs. This will guard against a tilted boring bar and assures that rebored cylinder wall is at right angles to crankshaft. 2. Measure piston, to be fitted, with a micrometer at center of piston skirt and at right angles to piston pin. Bore cylinder to same diameter as piston and hone cylinder to specifications (Section 8) and as outlined under "Cylinder Honing" and "Piston Selection", following. 3. Carefully follow instructions furnished by manufacturer of equipment being used. Cylinder Honing 1. Follow hone manufacturer's recommendations for use of hone and cleaning and lubrication during honing. 2. Occasionally, during honing operation, thoroughly clean cylinder bore and check piston for correct fit in cylinder. 3. W:hen finish honing a cylinder bore to fit a piston, move hone up-and-down to obtain very fine uniform surface finish marks in a cross-hatch pattern of approximately 30° to cylinder bore. Finish marks should be clean but not sharp and free from imbedded particles and torn or folded metal. CAUTION: Handle pistons with care and do not attempt to force them thru cylinder until cylinder has been honed to correct size, as this type piston can be distorted thru careless handling. 4. Permanently mark piston for cylinder to which it has been fitted and proceed to hone cylinders and fit remaining pistons. 5. Thoroughly clean cylinder bores with hot water and detergent. Scrub well with a stiff bristle brush and rinse thoroughly with hot water. Be absolutely certain that no abrasive material is allowed to remain in cylinder bores, or it will rapidly wear new rings and cylinder bores in addition to bearings lubricated by contaminated oil. Swab bores several times with light engine oil with a clean cloth, then wipe with a clean, dry cloth. DO NOT clean cylinder with kerosene or gasoline. Clean remainder of cylinder block to remove excess material spread during honing operation. MERCRUISER ENGINE - 5A-29 PISTON SELECTION OVERSIZE PISTONS AVAILABLE 1. Check USED piston to cylinder bore clearance as follows: a. Measure "Cylinder Bore Diameter" with a telescope gauge (2/2" [63.5mm] from top of cylinder bore). b. Measure "Piston Diameter" (at skirt across center line of piston pin). c. Subtract piston diameter from cylinder bore diameter to determine "Piston to Bore Clearance". d. Determine if piston to bore clearance is in acceptable range. ("Specifications" Section 8) 2. If used piston is not acceptable, check "Oversize Pistons Available" chart, following, and determine if a new piston can be selected to fit cylinder bore within acceptable range. 3. If cylinder bore must be reconditioned, measure new pi*on diameter (across centerline of piston pin), then ho. e cylinder bore to correct clearance. 4. Mark piston to identify cylinder for which it was fitted. Metric Conversion: 1 "-25.4mm DISTRIBUTOR LOWER BUSHING INSPECTION and REPLACEMENT Mode ModeMode l ll Engin EnginEngin e ee Displacemen DisplacemenDisplacemen t tt (Cu (Cu(Cu . .. In. In.In. ) )) Piston Size .001" .005" .020" .030" 153,230 and 250 3.8760" to 3.8770" 3.9037" to 3.9059" 181 3.9963" to 3.9973" 3.8937" to 3.8957" 4.0138" to 4.0158" 292 3.8740" to 3.8750" 3.9038" to 3.9058" Distributor lower bearing is a bronze bushing pressed into NOTE: Later distributors use a bushing in distributor lower side of engine block. Its upper inside diameter pilots housing. Measuring clearance between cylinder block distributor shaft, and outside diameter (extending below bushing and distributor shaft is not needed, since shaft is block) pilots oil pump. undercut. Some engines have a thrust washer at upper end of bushing 1. Install Tool J-9534 into bushing and remove bushing with bore. Thrust washer, where used, may be replaced at same a slide hammer. (Figure 3) time bushing is replaced. 2. Clean bushing bore in block and check for burrs or damage. Lower bushing ordinarily will require only a clearance or wear check during engine overhaul. When distributor shaft-tobushing clearance exceeds .0035" (.089mm), replace bushing, as follows, with oil pump and distributor removed: Q 3. Use Tool J-9535 with driver-bolt in driver handle to install driver into new bushing from large inside diameter. 4. Position bushing and driver to block and drive bushing in position (Figure 4), which is determined by tool bottoming against block. 977 R1 5C-30 -MERCRUISER ENGINE 5. Remove tool from bushing. It is possible that bushing with of driver handle. minimum inside diameter will collapse enough during installation to slightly seize installer arbor. If this happens, remove installer tool with slide hammer in driver bolt hole NOTE: This will not damage bushing, and tool is designed for this purpose, should it occur. 01614 With OIL NOZZLE REPLACEMENT 1. Remove nozzle with pliers. (Figure 5) 2. Drive new nozzle in place (oil hole in vertical position) with a suitable light plastic or rubber hammer. Figure 5. Oil Nozzle Replacement OIL FILTER BYPASS VALVE and REPLACEMENT oil filter removed, check spring and fibre valve for operation. Inspect for a cracked or broken valve. If replacement is necessary, pry valve out with screwdriver. Install and seat a new valve by tapping in place with a 9/16 thin-wall deep socket. (Figure 6) Figure 6. Oil Filter By-Pass Valve 977 R1 MERCRUISER ENGINE - 5A-31 SECTION 5 - ENGINE INDEX Page Engine Mechanical • V-8 (302 and 351 Cu. In.) Ford Engine 5B-1 Tools 5B-1 General 5B-1 Intake Manifold 5B-1 Removal 5B-1 Cleaning 5B-2 Inspection 5B-2 Installation 5B-2 Exhaust Manifolds 5B-2 Removal 5B-2 Cleaning and Inspection 5B-2 Installation 5B-3 Rocker Arm Cover 5B-3 Removal 5B-3 Installation 5B-3 Valve Clearance 5B-3 Valve Mechanism 5B-4 Removal 5B-4 Cleaning 5B-4 Inspection 5B-4 Installation 5B-4 Hydraulic Valve Lifters 5B-5 Locating Noisy Lifters 5B-5 Removal 5B-5 Type I Disassembly 5B-5 Type I Reassembly 5B-5 Type II Disassembly 5B-6 Type II Reassembly 5B-6 Cleaning 5B-6 Inspection 5B-6 Installation 5B-6 Valve Spring, Retainer and Stem Seal Replacement ...............5B-6 Cylinder Head 5B-7 Removal 5B-7 Disassembly 5B-7 Cleaning 5B-7 Inspection 5B-7 Cylinder Head Flatness 5B-7 Valve Seat Runout 5B-8 Valve Inspection 5B-8 Valve Seat Width 5B-8 Valve Stem Clearance 5B-8 Valve Spring Pressure 5B-9 Valve Spring "Square" 58-9 Reaming Valve Guides 5B-9 Refacing Valve Seats 5B-10 Rocker Arm Stud Replacement 5B-10 Valves 5B-11 Refacing Valves 5B-11 Reassembly 5B-11 Installation 5B-12 Oil Pan 5B-13 Removal 5B-13 Cleaning 5B-13 Inspection 5B-13 Installation 5B-13 Oil Pump 5B-13 Removal 5B-13 Disassembly 5B-13 Inspection 5B-13 Reassembly 5B-14 Installation 5B-14 Flywheel 5B-15 Removal 5B-15 Inspection 5B-15 InstallationPiston AssemblyRemovalDisassembly Cleaning Inspection Reassembly Fining Piston Rings Installation Connecting RodsRemoval and DisassemblyCleaningInspectionReassembly and Installation CrankshaftRemovalCleaningRefinishing JournalsInspectionInstallationCrankshaft End PlayCrankshaft Rear Oil Seal Replacement Main BearingsChecking ClearanceReplacement Connecting Rod BearingsChecking Clearance and Replacement Main and Connecting Rod Bearing InsertsCleaningInspection Torsional DamperRemovalCleaningInspectionInstallation Cylinder Block Front Cover and Front SealRemovalFront Oil Seal ReplacementInstallation Timing Chain. Sprockets and Fuel Pump Eccentric . .........5B-28 5B-15 5B-16 5B-16 5B-16 5B-16 5B-16 5B-16 5B-17 5B-18 58-19 5B-19 5B-19 5B-19 5B-19 5B-20 5B-20 5B-20 5B-20 5B-20 5B-21 5B-22 5B-22 5B-24 5B-24 5B-24 5B-25 5B-25 5B-26 5B-26 5B-26 5B-27 5B-27 5B-27 5B-27 5B-27 5B-27 5B-27 5B-27 5B-28 Removal 5B-28 Timing Chain and Sprockets 5B-28 Cleaning 5B-28 Inspection 5B-28 Fuel Pump Eccentric 5B-28 Cleaning 5B-28 Inspection 5B-28 Timing Chain Deflection 5B-28 Installation 5B-29 Camshaft 5B-30 Removal 5B-30 Cleaning and Inspection 5B-30 Installation 5B-30 Camshaft Bearing Replacement 5B-30 Camshaft Lobe Lift 5B-31 Camshaft End Play 5B-32 Cylinder Block 5B-32 Cleaning 5B-32 Inspection 5B-33 Refinishing Cylinder Walls 5B-33 Fitting Pistons 5B-33 To Fit a Piston 5B-34 Repairing Cylinder Block 5B-34 Core Plug Replacement 5B-34 Removal 5B-34 Installation 5B-34 ENGINE MECHANICAL V-8 (302 and 351 Cu. In.) FORD ENGINE TOOLS * All "J" Prefix (Special) Tools Listed Herein May Be Purchased from: Kent-Moore, Inc. 28635 Mound Road Warren, Michigan 48089 * All "T" Prefix (Special) Tools Herein May Be Purchased from: Owatonna Tools, Inc. Attn: Ford Order Desk Owatonna, Minnesota 55060 * If ordering tool number(s) shown in discussion on following pages, number(s) may be superseded by newer tool(s) which will be sent by tool manufacturer listed above. GENERAL Some repairs, which are listed in this section, must be Right hand and left hand rotation engines have similar repair completed with the engine removed from the boat. Type of procedures, as oudined in this section. Component repair and boat design determine if the engine is to be crankshafts, camshafts, front and rear crankshaft seals and removed. circulating water pumps, however, vary between right and left Place engine on an engine stand for major repairs. hand rotating engines. INTAKE MANIFOLD NOTE: Intake manifold and related parts are shown in 2. Remove coil bracket bolt and move coil aside. Figure 1. 3. Remove temperature sender leads. 4. Remove distributor cap and move cap aside. REMOVAL 5. Remove 2 bolts which secure thermostat housing to intake 1. Drain water from cylinder block. manifold. 1 - Intake Manifold 2 - End Gaskets 3 - Side Gaskets (2) 4 - Baffle 5 - Screw (2) 6 - Lifting Eve 7 - Screw (2) 8 - Stud (4) 9 - Nut (4) 10 - Bolt (8) Figure 1. Intake Manifold and Related Parts 274 MERCRUISER ENGINE - 5B-1 6. Remove carburetor fuel inlet line and throttle linkage. 8. Connect crankcase vent hose. Install coil. 7. Disconnect crankcase vent hose at rocker arm cover. 9. Connect throttle linkage. 8. Remove manifold attaching bolts and nuts. Remove 10. Install distributor cap. manifold and carburetor as an assembly. It may be 11. Operate engine at fast idle and check all hose connectior necessary to pry intake manifold away from cylinder and gaskets for leaks. When engine temperatures ha\ head(s). Use caution to avoid damage to gasket sealing stabilized, adjust engine idle speed and idle fuel mixture. surfaces. 9. Remove intake manifold gaskets and seals. Discard intake manifold attaching bolt sealing washers. CLEANING 1. Remove all gasket material from machined surfaces of manifold. 2. Clean manifold in a suitable solvent and dry with compressed air. INSPECTION 1. Inspect manifold for cracks, damaged gasket surfaces or other defects. 2. Replace studs which are stripped or damaged. 3. Remove all filings and foreign matter that may have entered manifold during repair. INSTALLATION 1. If replacing manifold assembly, transfer engine lifting eye, temperature sending unit, carburetor and spacer. Install new gasket. 2. Clean mating surface of intake manifold, cylinder heads and cylinder block. Use a suitable solvent to remove all traces of oil. Coat cylinder block seal surfaces with Perfect Seal (C-92-34227). ' 3. Position new seals on cylinder block and new gaskets on cylinder heads with gaskets interlocked with seal tabs. Be sure that holes in gaskets are aligned with holes in cylinder heads. 4. Carefully lower intake manifold into position on cylinder block and cylinder heads. After intake manifold is in place, run a finger around the seal area to make sure that seals are in place. 5. Be certain that holes in manifold gaskets and manifold are in alignment. Using new sealing washers, install intake manifold attaching bolts and nuts. Torque intake manifold bolts in 2 steps. Torque all bolts in sequence to specifications. After completing remaining assembly steps, operate engine until it reaches normal operating temperature, then retorque manifold bolts to specifications in sequence shown in Figure 2. 6. Install thermostat housing and temperature sender lead. 7. Install carburetor fuel inlet line. EXHAUST MANIFOLDS REMOVAL CLEANING and INSPECTION 1. Drain water from engine and manifolds. Remove cooling hose from manifold. 1. Clean gasket material from all surfaces and wash parts in 2. Remove dipstick bracket and fuel filter mount from port solvent. manifold. 2. Inspect all parts carefully. Machined surfaces must be clear 3. Remove solenoid bracket (if required). and free of all marks or deep scratches, or water and/or 4. Disconnect exhaust hoses. Drain water from manifold exhaust leaks may result. housing and elbow. 3. Check water passages for sand, silt or foreign material. 5. Remove attaching bolts and washers, then remove Passages must be clean for efficient cooling. manifold. 4. Pipe plugs may be removed from exhaust manifold elbow 5B-2 - MERCRUISER ENGINE 1 - Screw 2 - Clip 3 End Cap 4 - Gasket 5 - Water Drain Plug 6 - Screw (8) 7 - Washer (8) 8 - Plug (2) 9 Exhaust Manifold 10 - Gasket 11 - End Cap 12 - Screw 13-Screw (4) 14 - Lifting Eye 15 - Screw (2) 16 - Gasket 17 - Stud (4) 18 - Exhaust Elbow Plate 19 - Gasket (2) 20 - Water Drain Plug 21 Exhaust Elbow 22 Lockwasher (4) 23 Nut (4) 24 Fitting 25 - Plug 26 - Screw (4) 27 Clamp (4) 28 Exhaust Bellows 29 Exhaust Elbow 1 - Screw 2 - Clip 3 End Cap 4 - Gasket 5 - Water Drain Plug 6 - Screw (8) 7 - Washer (8) 8 - Plug (2) 9 Exhaust Manifold 10 - Gasket 11 - End Cap 12 - Screw 13-Screw (4) 14 - Lifting Eye 15 - Screw (2) 16 - Gasket 17 - Stud (4) 18 - Exhaust Elbow Plate 19 - Gasket (2) 20 - Water Drain Plug 21 Exhaust Elbow 22 Lockwasher (4) 23 Nut (4) 24 Fitting 25 - Plug 26 - Screw (4) 27 Clamp (4) 28 Exhaust Bellows 29 Exhaust Elbow Figure 3. Exhaust Manifold (Starboard) and Related Parts and exhaust pipe elbow, if more thorough inspection is gaskets and install attaching bolts and washers. Torque desired. bolts to specifications from center to ends. 3. Install exhaust hoses and drain plugs. 4. Install dipstick housing bracket and fuel filter on port INSTALLATION manifold. 1. Clean mating surfaces of exhaust manifold and cylinder 5. Install solenoid bracket (if required). head. 6. Install cooling inlet hose. 2. Position exhaust manifold on cylinder head with new-7. Start engine and check for leaks. ROCKER ARM COVER REMOVAL INSTALLATION 1. Remove carburetor vent hose from starboard cover. 1. Clean gasket surfaces and position cover(s) in place with 2 Remove attaching bolts and remove rocker arm cover(s). new gasket. 2. Install rocker cover bolts (with harness clamps on right manifold) and torque cover(s) to specifications shown in Section 8. 3. Install carburetor vent hose in rocker cover(s). VALVE CLEARANCE If a noise is present in valve train (which is not caused by a collapsed hydraulic lifter), use the following procedure to check for worn components in the valve train. If check indicates that clearance is not to specifications, replace worn parts in valve train to bring limit within specifications. 1. Position No. 1 piston at TDC (position "A" ) at end of compression stroke. Use chalk to mark points "B " and "C " approximately 90° apart. (Figure 4) Adjust only- valves indicated for position "A". 274 MERCRUISER ENGINE 5B- 3 2. Apply pressure on valve lifter with Tool 6513AC (Figure 5) to slowly bleed lifter until plunger is completely bottomed. 3. Hold valve lifter in full collapsed position and check available clearance with feeler gauge between rocker am and valve stem tip. (Figure 5) Feeler gauge width must not exceed 3/8" (9.5mrn). Clearance should be .083" to .183" (2.1mm to 4.6mm). Parts must be replaced if worn beyond specification. 4. Rotate crankshaft 180° (to position "B") clockwise from position "A". Repeat Steps 2 and 3 on appropriate valves. 5. Rotate crankshaft 270° (to position "C") clockwise from position "B". Repeat Steps 2 and 3 on appropriate valves. Figure 4. Position of Crankshaft for Checking Valve Clearance POSITION "A" With No. 1 piston on TDC at end of compression stroke (position "A " in Figure 4), check the following valves on 302 and 351 cu. in. engines: a. No. 1 intake, No. 1 exhaust b. No. 4 intake, No. 3 exhaust c. No. 8 intake, No. 7 exhaust POSITION "B" Rotate crankshaft to position "B" in Figure 4 and check the following valves on 302 and 351 cu. in. engines: a. No. 3 intake, No. 2 exhaust b. No. 7 intake, No. 6 exhaust POSITION "C" Rotate crankshaft to position "C" in Figure 4 and check the following valves on 302 and 351 cu. in. engines: a. No. 2 intake. No. 4 exhaust b. No. 5 intake, No. 5 exhaust c. No. 6 intake, No. 8 exhaust VALVE MECHANISM NOTE: Valve mechanism is shown in Figure 6. REMOVAL 1. Remove rocker arm cover(s) as outlined. 2. Remove rocker arm stud nut, ball unit and rocker arm. NOTE: Keep all parts in order when removed (to reinstall in same location). 3. Remove push rod(s) and identify (to reinstall in same location). CLEANING Clean all parts thoroughly in solvent. Make sure that all oil passages are open. Be certain that oil passage in push rod end of rocker arm is open. 977 R1 Figure 5. Checking Valve Clearance Figure 6. Valve Mechanism and Related Parts 5C-4 - MERCRUISER ENGINE INSPECTION Check rocker arm pad. side rails and ball seat for excessive wear, cracks, nicks or burrs. Check rocker arm stud and nut for stripped or broken threads. Check ends of push rods for nicks, grooves, roughness or excessive wear. Check push rods visually for straightness while they are installed in engine by rotating rods with valve closed. Push rods also can be checked with a dial indicator. INSTALLATION 1. Apply engine oil to top of valve stem and ball units. 2. Install rocker arm, ball unit and stud nut. 3. Install rocker arm cover(s) as outlined, preceding. HYDRAULIC VALVE LIFTERS NOTE: Hydraulic lifters are shown in Figures 7 and 8. Hydraulic valve lifters require little attention. Lifters are extremely simple in design, readjustments are not necessary and servicing requires only that care and cleanliness are exercised in the handling of parts. LOCATING NOISY LIFTERS Locate a noisy valve lifter by using a piece of garden hose approximately 4 ft. (1.2m) in length. Place one end of hose near end of each intake and exhaust valve, with other end of hose to the ear. In this manner, the sound is localized, making it easy to determine which lifter is at fault. Another method is to place a finger on face of valve spring retainer. If lifter is not functioning properly, a distinct shock will be felt when valve returns to its seat. General types of valve lifter noise are as follows: 1. Hard rapping noise -- Usually caused by plunger becoming tight in bore of lifter body so that return spring cannot push plunger back up to working position. Probable causes are: a. Excessive varnish or carbon deposit, causing abnormal stickiness. b. Galling or "pick-up" between plunger and bore of lifter body, usually caused by an abrasive piece of dirt or metal wedged between plunger and lifter body. 2. Moderate rapping noise - Probable causes are: a. Excessively high leakdown rate. b. Leaky check valve seat. c. Improper adjustment. 3. General noise throughout valve train - This will, in most cases, be a definite indication of insufficient oil supply or improper adjustment. 4. Intermittent clicking - Probable causes are: a. A microscopic piece of dirt momentarily caught between ball seat and check valve ball. b. In rare cases, ball itself may be out-of-round or have a flat spot. c. Improper adjustment. In most cases, where noise exists in one or more lifters, ail lifter units should be removed, disassembled, cleaned in solvent, reassembled and reinstalled in engine. If dirt, corrosion, carbon, etc, is shown to exist in one unit, it more likely exists in all the units, thus it would only be a matter of time before all lifters caused trouble. REMOVAL 1. Remove intake manifold as outlined. 2. Remove valve mechanism as outlined. 3. Remove valve lifters. NOTE: Place valve lifters in a rack so that they may be reinstalled in the same location. Internal parts of each hydraulic valve lifter assembly are matched sets. Do not intermix parts. Keep assemblies intact until cleaning. Disassembly and assembly procedures vary for Types I and II valve lifters. See Figures 7 and 8 for identification. TYPEI DISASSEMBLY Disassemble and assemble each lifter separately. Identify' lifter assemblies so that they will be reinstalled in original bores. 1. Grasp lock ring with needle-nose pliers to release ring from groove. It may be necessary to depress plunger to fully release lock ring. 2. Remove push rod cup, metering valve (disc), plunger and spring. 3. Remove plunger assembly, check valve and check valve retainer and plunger spring. Carefully remove plunger spring, check valve relainer and check valve disc from plunger. TYPE I REASSEMBLY (Figure 7) 1. Place plunger upside down. 2. Place check valve (disc or ball check) in position over oil hole on bottom of plunger. Set check valve spring on top of check valve (disc or ball check). 3. Position check valve retainer over check valve and spring and push retainer down into place on plunger. Check Valve Retainer Figure 7. Type I Hydraulic Valve Lifter Assembly 4. Place plunger spring and plunger (open end up) into lifter body. 5. Position metering valve (disc) in plunger, then place push rod cup in plunger. 6. Depress plunger and position closed end of lock ring in groove of lifter body. With plunger still depressed, position MERCRUISER ENGINE - 5B-5 open ends of lock ring in groove. Release plunger, then depress it again to fully seat lock ring. TYPE H DISASSEMBLY Each valve lifter is a matched assembly. If parts of one lifter are intermixed with parts of another, improper valve operation may result. Disassemble and assemble each lifter separately. Keep lifter assemblies in proper sequence so that they will be reinstalled in original bores. 1. Grasp lock ring with needle-nose pliers to release ring from groove. It may be necessary to depress plunger to fully release lock ring. 2. Remove push rod cup, metering valve disc and upper metering valve. Do not bend metering valve or valve tensioning finger. 3. Remove plunger assembly, check valve and check valve retainer and plunger spring. Carefully remove plunger spring, check valve retainer and check valve disc from plunger. TYPEU REASSEMBLY (Figure 8) 1. Place plunger in an inverted position and center check valve disc on plunger. Carefully slide check valve over disc and down until valve bottoms. A slight turning motion will help. Use every precaution not to distort valve in any way, nor to bend preformed fingers. With slight turning motion, slide plunger spring over metering valve and down until spring seats. 2. Leaving assembly inverted, slide lifter body down over spring until body slightly compresses spring. 3. Place combined assembly right-side-up on work surface. 4. Position upper metering valve in plunger, taking care not to tilt it to either side and not to damage or bend valve tensioning finger. Place metering valve disc over metering valve and install push rod cup. Depress cup and install lock ring. CLEANING Thoroughly clean all parts in cleaning solvent and wipe them with a clean, lint-free cloth. INSPECTION 1. Inspect parts and discard entire lifter assembly if any part shows pitting, scoring, galling, excessive wear or evidence or non-rotation. 2. Replace entire assembly, if plunger is not free in body. Plunger should drop to bottom of body by its own weigh when assembled dry. 3. Assemble lifter assembly and check for freedom ol operation by pressing down on push rod cup. LIFTER ASSEMBLY Figure 8. Type II Hydraulic Valve Lifter Assembly INSTALLATION 1. Install valve lifters. NOTE: Whenever valve lifters are being installed, coat foot of valve lifters with engine oil. 2. Install intake manifold as outlined. 3. Install and adjust valve mechanism as outlined. VALVE SPRING, RETAINER and STEM SEAL REPLACEMENT 1 - Valve Stem Key (2 per valve) 2 - Retainer 3 - Seal 4 - Valve Spring 5 - Valve Figure 9. Valve and Related Parts NOTE: Valve and related parts are shown in Figure 9. Broken valve springs or damaged valve stem seals and retainers may be replaced without removing cylinder head if no damage to valve or valve seat. 1. Remove valve rocker arm cover and spark plug of cylinder that valve spring will be removed. 2. Remove valve rocker arm stud nuts, ball units, valve rocker arms and push rods from applicable cylinder. 3. Install an air line with adaptor in spark plug hole and turn on air. 4. Install stud nut and position compressor tool as shown in Figure 11. Compress valve spring and remove retainer locks, spring retainer and valve spring. 5. Remove and discard valve stem seal. 977 R1 5C-6 - MERCRUISER ENGINE valve stem tip for eccentric movement during rotation. 8. If condition of valve is satisfactory, hold valve in closed position and apply air pressure to cylinder. 9. Install a new valve stem seal. (Figure 10) Place spring in position over valve and install valve spring retainer. Compress valve spring and install valve spring retainer locks. (Figure 11) Remove compressor tool and stud nut. 10. Install valve mechanism as outlined. 11. Remove air line and adaptor. Install spark plug and wire. 12. Install rocker arm cover as outlined. 4 Figure 10. Compressing Valve Spring 6. If air pressure has forced piston to bottom of cylinder, any removal of air pressure will allow valve(s) to fall into cylinder. A rubber band, tape or string (wrapped around end of valve stem) will prevent valve(s) from dropping and still allow enough travel to check the valve for binds. Move valve up and down thru normal travel in valve guide and check stem for binds. If valve has been damaged, Air Line Tool T62F-6565-A Q601 3 remove cylinder head for repairs as outlined, following. 7. Inspect valve stem for damage. Rotate valve and check Figure 11. Removing or Installing Valve Stem Seal CYLINDER HEAD If replacing a cylinder head, follow procedures under "Cylinder Head Disassembly and Assembly", following, and transfer all valves, springs, spark plugs, etc, to new cylinder head. Clean and inspect all parts, reface valves and check all assembly clearances before assembling new or used parts to new cylinder head. REMOVAL 1. Remove intake manifold as outlined. 2. Remove exhaust manifold(s) as outlined. 3. Remove rocker arm cover(s) as outlined. 4. Loosen distributor cap and remove spark plug wire hold-down. Remove plug wires and distributor cap as an assembly. 5. Remove spark plugs. 6. Remove valve mechanism as outlined. 7. Remove cylinder head attaching bolts and lift cylinder head off block. DISASSEMBLY 1. Clean carbon out of cylinder head combustion chambers before removing valves. 2. Compress valve springs. (Figure 11) Remove spring retainer locks and release spring. 3. Remove spring retainer, spring, stem seal and valve. Discard valve stem seals. Identify all valve parts (to reinstall in same location). 4. Clean, inspect and repair cylinder head, as required, or transfer all usable parts to a new cylinder head. CLEANING 1. With valves installed to protect valve seats, remove deposits from combustion chambers and valve heads with a scraper and wire brush. Be careful not to damage cylinder head gasket surface. 2. After removing valves, clean valve guide bores with a valve guide cleaning tool. Use cleaning solvent to remove dirt, grease and other deposits. 3. Clean all bolt holes and remove all deposits from valves with a fine brush or buffing wheel. INSPECTION Check cylinder head for cracks and inspect gasket surface for burrs and nicks. Replace head if cracked. CYLINDER HEAD FLATNESS When a cylinder head is removed because of gasket leaks, check cylinder head for flat gasket surface according to specifications. (Figure 12) If necessary to refinish cylinder head gasket surface, do not plane or grind off more than .010" (.25mm). MERCRUISER ENGINE - 5B-7 Figure 12. Typical Cylinder Head Flatness VALVE SEAT RUNOUT Check valve seat runout with accurate gauge. (Figure 13) Follow instructions of gauge manufacturer. If runout exceeds wear limit, reface valve and valve seat. Runout Gauge 06017 Figure 13. Checking Valve Seat Runout VALVE INSPECTION 1. The critical inspection points and tolerances of valves are illustrated in Figure 14. Refer to specifications for wear limits. Figure 14. Critical Valve Dimensions 5C-8 - MERCRUISER ENGINE 2. Inspect valve face and edge of valve head for pits, grooves, scores or other damage. 3. Inspect stem for bent condition and end of stem for grooves or scores. 4. Check valve head for signs of burning, erosion, warpi and cracking. Minor pits, grooves, etc, may be removed. Discard valves that are severely damaged. 5. Inspect valve spring, valve spring retainers and locks for wear or damage. Discard any visually damaged parts. VALVE SEAT WIDTH Measure valve seat width. (Figure 15) Reface valve seats if width is not within specifications. Figure 15. Checking Valve Seat Width Figure 16. Checking Valve Stem Clearance VALVE STEM CLEARANCE 1. Measure valve stem clearance (Figure 16) as foliowr Clamp a dial indicator on one side of cylinder head rock arm cover gasket rail, locating indicator so that movement of valve stem from side to side (crosswise to the head) will cause a direct movement of indicator stem. Indicator stem must contact side of valve stem just above valve guide. 2. With valve head dropped about 1/16" (1.6mm) off valve 977 R1 seat, move valve stem from side-to-side, using light pressure to obtain a clearance reading. 3. If clearance exceeds specifications, it will be necessary to ream valve guides for oversize valves, as outlined. VALVE SPRING PRESSURE 1. Check springs for correct pressure at specified spring lengths with Tool J-8056. (Figure 17) IMPORTANT: DO NOT manually rotate valve assemblies while installed in engine to determine and/or bad valve springs. Weak valve springs cause engine performance. 2. Replace any spring not within specifications. spring good poor 01594 Figure 17. Checking Valve Spring Pressure VALVE SPRING "SQUARE" 1. Check each spring for "square" with a steel square and flat surface. (Figure 18) 2. Stand spring and square on end on flat surface. Slide spring up to square. 3. Revolve spring slowly and observe space between top coil of spring and square. Out-of-square limits are 5/16" (8mm). 4. Follow same procedure to check new valve springs before installation. IMPORTANT: Make certain that proper spring (color coded) is installed. 5. Visually inspect valve spring retainer to determine if damper spring coil has been hitting retainer. This interference also will cause a clicking noise when engine is operating. Damper spring is properly installed in valve spring when positioned so that end of damper spring bottom coil is 135° counterclockwise from end of valve spring lower coil. Not More Than 5/64" Closed Coil End Downward Figure 18. Checking Valve Spring Squareness REAMING VALVE GUIDES 1. If valve stem to valve guide clearance exceeds the wear limit, ream valve guide for next oversize valve stem (.015" [.38mm] available). 2. Use Reaming Kit T526-6085-AEE when reaming a valve guide (Figure 19) to install valve with oversize stem. Kit has .003" (.075mm) OS reamer with standard diameter pilot and .015"OS reamer with .003" OS pilot. 3. When going from standard size valve to oversize valve, always use .063" oversize reamer before using .015" oversize finish-reamer. Reamer Break Sharp Corner 06019 Figure 19. Reaming Valve Guides MERCRUISER ENGINE -5B-9 IMPORTANT: Always reface valve seat after valve guide has been reamed and use a suitable scraper to break the sharp corner (ID) at top of valve guide. RE FACING VALVE SEATS 1. Closely coordinate refacing valve seat with refacing valve face so that finished seat and valve face are concentric, and specified interference fit will be maintained. This is important so that valve and seat have a compression-tight fit. Be sure that refacer grinding wheels are properly dressed. 2. Grind valve seats to a true 45° angle. (Figure 20) Remove only enough stock to clean up pits and grooves or to correct valve seat runout. After seat has been refaced, use a seat width scale or a machinist scale to measure seat width. (Figure 20) Narrow seat, if necessary, to meet specifications. 3. If valve seat width exceeds maximum limit, remove enough stock from top edge and/or bottom edge of seat to reduce width to specifications. 4. On valve seats of all engines, use a 60° angle grinding wheel to remove stock from bottom of seats (raise seats) and use a 30° angle wheel to remove stock from top of seats (lower seats). 5. Finished valve seat should contact approximate center of valve face. It is good practice to determine where valve seat contacts face by coating seat with Prussian blue and setting valve in place. Rotate valve with light pressure. If blue is transferred to center of valve face, contact is satisfactory. If blue is transferred to top edge of valve face, lower the valve seat. If blue is transferred to bottom edge of valve face, raise valve seat. ROCKER ARM STUD REPLACEMENT 1. If necessary to remove a rocker arm stud, use Tool Kit T62F-6A527-B which contains a stud remover, a .006" (,15mm) oversize reamer and a .015" (.38mm) oversize reamer. 2. To press in replacement studs, use Stud Replacer T69P-6049-D. Figure 21. Removing Rocker Arm Stud 3. Broken or rocker arm studs with damaged threads may be replaced with standard studs. 4. Replace loose studs in head with .006" or .015" oversize studs which are available for service. 5. Identify standard and oversize studs by measuring stud diameter within 1-1/8" (28.6mm) from pilot end of stud. Stud diameters are: Standard : .3714"-.3721" .006" Oversize: .3774"-.7781 " .015 " Oversize: .3864 " -.3871" 6. When going from standard-size rocker arm stud to .015" oversize stud, always use .006" oversize reamer before finish-reaming with .015" oversize reamer. NOTE: Cut off threaded part of stud to permit remover tool installation. Figure 22. Reaming Rocker Arm Stud Bore 5C-10 - MERCRUISER ENGINE 977 R1 a. Position sleeve of rocker arm stud Remover Tool T62F-6A527-B over stud with bearing end down. Thread puller into sleeve and over stud until fully bottomed. Hold puller with wrench, then rotate sleeve clockwise to remove stud. (Figure 21) If rocker arm stud was broken off flush with stud boss, use an easy-out to remove broken stud, following instructions of tool manufacturer. b. If replacing a loose rocker arm stud, ream stud bore with correct reamer (or reamers in sequence) for selected oversize stud. (Figure 22) IMPORTANT: Make certain that metal particles DO NOT ENTER valve area. c. Use Tool T69P-6049-D when installing stud. (Figure 23) Positive Stop 06102 Figure 23. Installing Stud VALVES 1. Minor pits, grooves, etc, may be removed. Discard severely damaged valves, or if face runout or stem clearance exceeds specifications. 2. Discard any worn or damaged valve train parts. REFACING VALVES 1. Closely coordinate valve refacing operation with valve seat refacing operations so that finished angles of valve face and of valve seat will meet specifications and provide a compression-tight fit. Be sure that refacer grinding wheels are properly dressed. 2. If valve face runout is excessive and/or to remove pits and grooves, reface valves to a true 44° angle. Remove only enough stock to correct runout or to clean up pits and grooves. If edge of valve head is less than 1/32" (.8mm) thick after grinding, replace valve, as valve will run too hot in engine. Interference fit of valve and seat should not be lapped out. 3. Remove all grooves or score marks from end of valve stem and chamfer it as necessary. Do not remove more than 977 R1 .010" (,25mm) from end of the valve stem. Valve stem from valve lock groove to end (Figure 14, preceding) must not be shorter than minimum specified length. 4. If valve and/ or valve seat has been re faced, it will be necessary to check clearance between rocker arm seat and valve stem with valve train assembly installed in engine. REASSEMBLY 1. Install each valve in port from which it was removed or to which it was fitted. Install a new stem seal on valve. 2. Install valve spring over the valve, then install spring retainer. Compress spring and install retainer locks. (Figure 24) 06104 Figure 24. Valve Assembly SEE SPECIFICATIONS Figure 25. Measuring Spring Height MERCRUISER ENGINE - 5A-11 3. Measure assembled height of valve spring from surface of cylinder head spring seat to underside of spring retainer with dividers. (Figure 25) Check dividers against a scale. If assembled height is greater than or less than specifications, replace valve spring. INSTALLATION 1. Clean all gasket surfaces to obtain flat, smooth cylinder head and block mating. 2. Position new cylinder head gasket over cylinder head dowels on block. Position cylinder head on block and install attaching bolts. 3. Cylinder head bolts are tightened in 3 progressive steps. Torque all bolts in sequence and finally to specifications. (Figure 26) When head bolts have been tightened, following this procedure, it is not necessary to retorque Figure 26. Cylinder Head Bolt Torque Sequence bolts after extended operation. Bolts may be checked, however, and retorqued, if desired. 4. Install valve mechanism as outlined, preceding. 5. Install rocker arm cover(s) as described previously. 6. Install intake manifold as outlined, preceding. 7. Install exhaust manifolds as described previously. 5C-12 - MERCRUISER ENGINE 977 R1 OIL PAN REMOVAL 1. Drain crankcase. Remove oil level dipstick and tube. 2. Remove seawater pump adjustment bracket. 3. Remove attaching screws and washers and remove oil pan. CLEANING 1. Scrape any dirt or metal particles from inside of pan. 2. Scrape all old gasket material from gasket surface. 3. Wash pan in solvent and dry thoroughly. Be sure that all foreign particles are removed from below baffle plate. INSPECTION 1. Check pan for cracks, holes, damaged drain plug threads and loose baffle or damaged gasket surface. 2. Inspect for damage (uneven surface caused by overtorquing bolts) at bolt holes. Straighten surfaces as required. 3. Repair any damage or replace pan if repairs cannot be made. INSTALLATION 1. Before installing aluminum oil pan, coat surfaces of front and rear oil pan gasket (rubber) (Figure 1) with Silicone Sealant (C-92-52238-1). 2. Clean gasket surfaces of block and oil pan. Oil pan has a 2-piece gasket. Coat block surface and oil pan gasket with Perfect Seal (C-92-34227). Position oil pan gaskets on cylinder block. 3. Position oil pan front seal on cylinder block front cover. OIL NOTE: Oil pump assembly is shown in Figure 4. REMOVAL 1. Remove oil pan as outlined, preceding. 2. Remove oil pump attaching bolts and remove oil pump, gasket and intermediate drive shaft. DISASSEMBLY 1. Remove oil inlet tube from oil pump and remove gasket. 2. Remove cover attaching screws and cover. Remove inner rotor and shaft assembly, then remove outer race. 3. Insert a self-threading sheet metal screw of proper diameter into oil pressure relief valve chamber cap and pull cap out of chamber. Remove spring and plunger. CLEANING 1. Wash all parts in a solvent and dry them thoroughly with compressed air. 2. Clean inside of pump housing and pressure relief valve chamber with a brush. Be sure that all dirt and metal particles are removed. 4. Position oil pan rear seal on rear main bearing cap. (Figure 1) Be sure that tabs on seals are over oil pan gasket. 5. Install oil pan bolts, torquing to specifications from center outward in each direction. 6. Install oil level dipstick tube and dipstick. Fill crankcase with correct grade and quantity of engine oil. Start engine and check for oil leaks. Figure 1. Oil Pan Gaskets and Seals Installed PUMP INSPECTION 1. Check inside of pump housing and outer race and rotor for damage or excessive wear. 2. Replace cover if cover mating surface is worn, scored or grooved. 3. Measure outer race to housing clearance (min. .006" [,15mm] to max. .013" [,33mm]). (Figure 2) 4. With rotor assembly installed in housing, place a straight edge over rotor assembly and housing. Measure clearance (rotor end play) between straight edge and rotor and outer race (min. .0011" [,028mm] to max. .0041" [.104mm]). (Figure 3) NOTE: Outer race, shaft and rotor are replaceable as an assembly. 5. Check drive shaft to housing bearing clearance by measuring OD of shaft and ID of housing bearing (min. .0015" to max. .0029"). 6. Inspect relief valve spring for collapsed or worn condition. If worn or damaged replace spring. 7. Check relief valve piston for scores and free operation in bore. 5B-13 - MERCRUISER ENGINE 274 Figure 2. Checking Outer Race to Housing Clearance Figure 3. Checking Rotor End Play REASSEMBLY 06099 Oil pump assembly is shown in Figure 4. 1. Oil all parts thoroughly. 2. Install oil pressure rfelief valve plunger, spring and new cap. 3. Install outer race and inner rotor and shaft assembly. Be sure that dot (identification mark) on outer race is facing outward and on same side as identification mark on rotor. (Figure 2) The race rotor and shaft and outer race are serviced as an assembly. Do not replace one part without replacing other. 4. Install cover and torque cover attaching screws to 9 to 12 ft. lbs. (1.24 to 1.66mkg). 5. Position new gasket and oil inlet tube on oil pump and install attaching bolts. Torque to 12-15 ft. lbs. (1.66 to 2.07mkg). Figure 4. Oil Pump Assembly INSTALLATION 1. Prime oil pump by filling either inlet or outlet port with engine oil. Rotate pump shaft to distribute oil within pump body. 2. Position intermediate drive shaft into distributor socket. With shaft firmly seated in distributor socket, stop on shaft should touch roof of crankcase. Remove shaft and position stop as necessary. 3. Position new gasket on pump housing. With stop properly positioned, insert intermediate drive shaft into oil pump. Install pump and shaft as an assembly. IMPORTANT: Do not attempt to force pump into position if it will not seat readily. Drive shaft hex may be misaligned with distributor shaft. To align, rotate intermediate drive shaft into a new position. 4. Torque oil pump attaching screws to 23 to 28 ft. lbs. (3.18 to 3.87mkg). 5. Install oil pan and related parts as outlined under "Oil Pi Installation", preceding. 5B-14 - MERCRUISER ENGINE FLYWHEEL REMOVAL 1. Remove all attaching parts from flywheel housing. 2. Remove transmission (if so equipped). 3. Remove flywheel cover and housing. 4. Remove drive plate or engine coupling from flywheel. 5. Remove flywheel attaching bolts and remove flywheel. INSPECTION I. Inspect flywheel for cracks or other damage that may make it unfit for further service. 2. Inspect ring gear for worn, chipped or cracked teeth. If teeth are damaged, replace flywheel. INSTALLATION 1. Position flywheel on crankshaft flange. Install and torque bolts in sequence across from each other. 2. Install drive plate or engine coupling. 3. Install flywheel housing and cover. 4. Install all parts which were removed from flywheel housing. 5. Install transmission (if so equipped). MERCRUISER ENGINE - 5B-15 Figure 1. Removing or Installing Piston Pin 5B-16 - MERCRUISER ENGINE PISTON ASSEMBLY NOTE: Piston and related parts are shown in Figure 3. DISASSEMBLY REMOVAL 1. Remove bearing inserts from connecting rod end cap. 2. Mark pistons and pins to assure reassembly on same rod 1. Drain water from cooling system and oil from crankcase. and installation in same cylinders from which they were Remove intake and exhaust manifolds, cylinder heads, oil removed. pan and oil pump as outlined. 3. Remove piston rings. 2. Remove any ridges and/or deposits from upper end of 4. Use an arbor press and tool (shown in Figure 1) and press cylinder bores as follows: piston pin from piston and connecting rod. a. Tum crankshaft until piston (to be removed) is at bottom of its travel and place a cloth on piston head to CLEANING collect cuttings. b. Remove any ridge and/or deposits from upper end of Remove deposits from piston surfaces. Clean gum or varnish cylinder bores. from piston skirt, piston pins and rings with solvent. DO NOT c. Remove cylinder ridge with a ridge cutter. Follow use a caustic cleaning solution or a wire brush to clean pistons. instructions furnished by tool manufacturers. Never Clean ring grooves with ring groove cleaner. (Figure 2) Make cut into ring travel area in excess of 1/32" (.8mm) sure that oil ring slots (or holes) are clean. when removing ridges. 3. Make sure that all connecting rod caps are marked to be reinstalled in original positions. 4. Turn crankshaft until connecting rod and piston assembly (being removed) is at bottom of stroke. 5. Remove connecting rod nuts and cap. 6. Push connecting rod and piston assembly out top of cylinder with handle end of a hammer. Avoid damage to crankshaft journal or cylinder wall when removing piston and rod. 7. Install cap on connecting rod from which it was removed. Figure 2. Cleaning Piston Ring Grooves - Typical INSPECTION 1. Carefully inspect pistons for fractures at ring lands, skirts and pin bosses and for scuffed, rough or scored skirts. If lower inner portion of ring grooves has a high step, replace piston. The step will interfere with ring operation and cause excessive ring side clearance. 2. Spongy, eroded areas near edge of top of piston usually are caused by detonation or pre-ignition. A shiny surface on thrust surface of piston, offset from centerline between piston pin holes, may be caused by a bent connecting rod. Replace pistons which show signs of excessive wear, wavy ring lands or fractures or damage from detonation or pre-ignition. 3. Check piston to cylinder bore clearance by measuring piston and bore diameters. Refer to specifications for proper clearance. Refer to "Cylinder Block Inspection" preceding, for bore measurement procedure. Measure OD of piston with micrometers at centerline of piston pin bore and at 90 ° to pin bore axis. Check ring side clearance following procedure under "Fitting Piston Rings" (see "Index"). 4. If wear is present in piston pin area, replace piston. 5. Replace all rings which are scored, chipped or cracked. Check end gap and side clearance. DO NOT transfer rings from one piston to another. REASSEMBLY Piston, connecting rod and related parts are shown in Figure 3. IMPORTANT: Check fit of a new piston in cylinder bore before assembling piston to connecting rod. Piston pin bore of a connecting rod and diameter of piston pin must be within specifications. 1. Assemble piston to connecting rod with cylinder number side of connecting rod and notch in piston positioned as shown in Figure 4. On replacement connecting rods, install large-chamfered side of connecting rod bearing bore toward crankshaft cheek, facing toward front of engine on right bank rods and facing toward rear of engine of left bank rods. NOTE: DO NOT oil piston pin, piston or connecting rod before rod end is to be heated for installation. Parts must be clean and dry. 2. Heat piston pin end of connecting rod. NOTE: An oven is recommended to heat piston pin end of connecting rod prior to piston installation. (Figure 5) 3. Start piston pin in piston and connecting rod (this may require a very light tap with a mallet). Using an arbor press, press piston pin thru piston and connecting rod until pin is centered in piston. (Figure 1) 4. Allow connecting rod and piston assembly to cool, then oil piston pin. Upper Lower Compression Compression Ring Ring 06030 Figure 3. Piston, Connecting Rod and Related Parts 977R1 5. Install piston rings. 6. Be sure that bearing inserts and bearing bore in connecting rod and cap are clean. Foreign material under inserts will distort bearing and cause a failure. Install bearing inserts in connecting rod and cap with tangs fitting in slots provided. Right Bank Left Bank Notch Toward Front of Engine Numbered Side of Rod 06032 Figure 4. Correct Piston and Rod Positions 04992 Figure 5. Heating Connecting Rod FITTING PISTON RINGS 1. Select proper ring set for size of cylinder bore. 2. Position ring in cylinder bore in which it is to be used. 3. Push ring down into bore area where normal ring wear is not encountered. 4. Use head of a piston to position ring in bore so that ring is square with cylinder wall. Use caution to avoid damage to ring or cylinder bore. 5. Measure gap between ends of ring with a feeler gauge. (Figure 6) If ring gap is less or greater than specified limits, try another ring set. 6. Check ring side clearance of compression rings with a feeler inserted between rinu and ils lower land. MERCRUISER ENGINE - 5C-17 (Figure 7) Gauge should slide freely around entire ring circumference without binding. Wear forms a step at inner Oil Ring Spacer portion of lowerreplace piston. land. If lower lands have high steps, Oil Ring Segment Oil Ring Segment Front of Engine 06027 Figure 8. Piston Ring Spacing 3. Make sure that ring gaps are properly spaced around circumference of piston. (Figure 8) 4. Install piston ring compressor on piston and push piston in with a hammer handle until piston is slightly below top of cylinder. (Figure 9) Be sure to guide connecting rods to avoid damaging crankshaft journals. Install piston with indentation notch in piston dome toward front of engine. Piston Ring Compressor INSTALLATION 1. If installing new piston rings, remove cylinder wall glaze. Follow instructions of tool manufacturer. 06028 2. Oil piston rings, pistons and cylinder walls with light engine oil. Figure 9. Installing Piston IMPORTANT: Be sure to install pistons in same cylinders 5. Turn crankshaft throw to bottom of its stroke. Push piston from which they were removed or to which they were down until connecting rod bearing seats on crankshaft fitted. Connecting rod and bearing caps are numbered journal. from l-to-4 in right bank and from 5-to-8 in left bank, 6. Check clearance of each bearing as outlined. beginning at front of engine. Numbers on connecting rod 7. After bearings have been fitted, apply light coat of engine and bearing cap must be on same side when installed in oil to journals and bearings. cylinder bore. If a connecting rod is ever transposed from 8. Install connecting rod cap. Torque nuts to specifications. one block or cylinder to another, fit new bearings and 9. After installing piston and connecting rod assemblies, number connecting rod to correspond with new cylinder check side clearance between connection rods on each number. crankshaft journal. (Figure 10) 06034 Figure 7. Checking Piston Ring Side Clearance 977 R1 5C-18 - MERCRUISER ENGINE 10. Disassemble, clean and assemble oil pump. Clean all gasket surfaces. 11. Prime oil pump by filling either inlet port or outlet port with engine oil and rotating pump shaft to distribute oil within housing. Install oil pump and oil pan. 12. Install cylinder heads, intake and exhaust manifolds. 13. Fill crankcase with correct engine oil. 14. Operate engine at fast idle and check for oil and coolant leaks. When engine temperature has stabilized, adjust engine idle speed and idle fuel mixture. Figure 10. Checking Connecting Rod Side Clearance CONNECTING RODS R EMOVAL and DISASSEMBLY either a bent connecting rod, an improperly machined crankpin or a tapered connecting rod bore. Refer to ''Piston Assembly, Removal - Disassembly" (see 3. Twisted connecting rods will not create a wear pattern "Index"). easy to identify, but badly twisted rods will disturb action of entire piston, rings and connecting rod assembly and CLEANING may cause excessive oil consumption. 4. Inspect connecting rods for signs of fractures and bearing Remove bearings from rod and cap. Identify bearings if bores for out-of-round and taper. If bore exceeds re-using. Clean connecting rod in solvent, including rod bore recommended limits and/or, if connecting rod is fractured, and back of inserts. DO NOT use a caustic cleaning solution. replace rod. Blow dry with compressed air. 5. If wear is present in piston pin hole, replace connecting rod. INSPECTION 6. Replace defective connecting rod nuts and bolts. 7. Check connecting rods for bend or twist on a suitable Carefully inspect connecting rods and related parts to meet alignment fixture. Follow instructions of fixture specifications. Various forms of engine wear, related to these manufacturer. If bend and/or twist exceeds specifications, replace connecting rod. [»arts, can be readily identified. 1. Shiny surface on pin boss side of piston usually indicates a bent connecting rod. or piston pin hole is not in proper REASSEMBLY and INSTALLATION relation to piston skirt and ring grooves. Refer to "Piston Assembly. Reassembly - Installation" (see 2. Abnormal connecting rod bearing wear may be caused by "Index"). 977R1 MERCRUISER ENGINE - 5C-19 CRANKSHAFT Crankshaft and related parts are shown in Figure 1. 6. Make sure that all bearing caps (main and connecting rod) are marked for re-installing in their original locations. Tun crankshaft until connecting rod (from which cap is being removed) is at bottom of stroke and remove bearing cap. REMOVAL Push connecting rod and piston assembly up into cylinder. 1. Remove flywheel and mount engine on ari engine stand. Repeat this procedure until all connecting rod bearing caps Turn engine to an inverted position. are removed. 2. Remove oil pan and oil pump as outlined, preceding. 7. Remove main bearing caps. 3. Remove cylinder block front cover as described previously. 8. Carefully lift crankshaft out of block so that thrust bearing 4. Remove spark plugs to allow easy rotation of crankshaft. surfaces are not damaged. Handle crankshaft with care to 5. Remove timing chain and sprockets as outlined. avoid possible fracture or damage to finished surfaces. CLEANING 1. Handle crankshaft with care to avoid possible fractures or damage to finished surfaces. Clean crankshaft with solvent, then blow out all oil passages with compressed air. 2. Use crocus cloth to remove sharp edges or burrs which might damage oil seal or bearing during installation or cause premature seal or bearing wear. DO NOT use crocus cloth to extent that seal surface becomes polished. A finely polished surface may produce poor sealing or cause premature seal wear. 3. If journals arc severely marred or exceed wear limit, re finish to size for nc\t undersize bearing. Flywheel REFINISHING JOURNALS 1. Refinish journals to give proper clearance with next undersize bearing. If journal will not clean up to maximum undersize bearing available, replace crankshaft. 2. After refinishing journals, chamfer oil holes, then polish journal with No. 320 grit polishing cloth and engine oil. Crocus cloth also may be used as a polishing agent. INSPECTION 1. Inspect main and connecting rod journals for cracks, scratches, grooves or scores. Inspect crankshaft oil seal 5C-20 - MERCRUISER ENGINE 977 R1 surface for nicks, sharp edges or burrs which might damage oil seal during installation or cause premature seal wear. 2. Measure diameter of each journal in at least 4 places to determine out-of-round, taper or undersize condition. (Figure 2) Figure 2. Crankshaft Journal Measurement INSTALLATION 1. Remove rear journal oil seal from block and rear main bearing cap. 2. Remove main bearing inserts from block and bearing caps. 3. Remove connecting rod bearing inserts from connecting rods and caps. 4. If crankshaft main bearing journals are refinished to a definite undersize, install correct undersize bearings. Be sure that bearing inserts and bores are clean. Foreign material under inserts will distort bearing and cause a failure. 5. Place upper main bearing inserts in position in bores with tang fitting in slot provided. 6. Install lower main bearing inserts in bearing caps. 7. Install crankshaft rear oil seal as outlined. 8. Carefully lower crankshaft into place. Be careful not to damage bearing surfaces. 9. After bearings are fitted, apply a light coat of engine oil to journals and bearings. Install new seal in rear main bearing cap and install rear main bearing cap by following steps under "Main Bearing Replacement" (see "Index"). Install all bearing caps, except thrust bearing cap (No. 3 bearing). Be sure that main bearing caps are installed in their original locations. Torque bearing cap bolts to specifications. 10. Install thrust bearing cap with bolts finger-tight. 11. Pry crankshaft forward against thrust surface of upper half of bearing. (Figure 3) 12. Hold crankshaft forward and pry thrust bearing cap to rear to align thrust surfaces of both halves of bearing. 13. Retain forward pressure on crankshaft. Tighten cap bolts to specifications. 14. Force crankshaft toward rear of engine. 15. Check crankshaft end play. 16. Install new bearing inserts in connecting rods and caps. Check clearance of each bearing following recommended procedure. 17. After fitting connecting rod bearings, apply a light coat of engine oil to journals and bearings. 18. Turn crankshaft throw to bottom of its stroke. Push piston all the way down until rod bearing seats on crankshaft journal. 19. Install connecting rod cap and torque nuts to specifications. 20. After installing piston and connecting rod assemblies, check side clearance between connecting rods on each connecting rod crankshaft journal. (Figure 4) 21. Install timing chain and sprockets. 22. Install cylinder block front cover. 23. Install oil pump and oil pan. 24. Remove engine from stand and install flywheel. 25. Install spark plugs. Figure 3. Aligning Thrust Bearing 977 R1 MERCRUISER ENGINE - 5A-21 06098 06098 Figure 4. Checking Connecting Rod Side Clearance Screwdriver crankshaft flange and indicator axis is parallel to crankshaft axis. (Figure 5) 3. Zero dial indicator. Push crankshaft forward and note reading on dial. 4. If end play exceeds wear limit, replace thrust bearing. * end play is less than minimum limit, inspect thrust bearing faces for scratches, burrs, nicks or dirt. If thrust faces are not damaged or dirty , they probably were not aligned properly. 5. Install thrust bearing and align faces following procedure recommended under "Main Bearing Replacement", (see "Index"). Check end play. CRANKSHAFT REAR OIL SEAL REPLACEMENT Replacing crankshaft rear oil seal to correct for oil leaks requires replacement of both upper and lower seal halves, as follows: 1. Remove oil pan as outlined. 2. Loosen all main bearing cap bolts to allow crankshaft to lower slightly but not to exceed 1/32" (.8mm). 3. Remove oil seal from bearing cap and cylinder block. Exercise caution to prevent scratching or damaging crankshaft seal surface. 4. Carefully clean seal grooves in cap and block with brush and solvent. 5. Dip split-lip type seal halves in clean engine oil. 6. Carefully install upper seal (cylinder block) into its groove with undercut side of seal toward FRONT of engine, (Figure 6) by rotating it on seal journal of crankshaft unti1 approximately 3/8" (9.5mm) protrudes below partir^ surface. IMPORTANT: Be sure that no rubber has been shaved from outside diameter of seal by bottom edge of groove. 7. Tighten remaining bearing cap bolts and torque to specifications. IMPORTANT: Split-lip seals are used as replacement seals. If rear main bearing cap has a rear seal retaining pin, pin must be removed or split-lip seal will be damaged. 8. Install lower seal in rear main bearing cap with undercut side of seal toward FRONT of engine. (Figure 6) Allow seal to protrude approximately 3/8" above parting surface Figure 5. Checking Crankshaft End Play to mate with upper seal when cap is installed. 9. Apply thin coat of Perfect Seal (C-92-34277) to rear main bearing cap at rear of top mating surface. DO NOT apply CRANKSHAFT END PLAY sealer to area forward of side seal groove. Install rear main 1. Force crankshaft toward rear of engine. bearing cap. Torque cap bolts to specifications. 2. Install dial indicator so that contact point rests against 10. Install oil pan as outlined. 5C-22 - MERCRUISER ENGINE 977 R1 Figure 6. Installing Crankshaft Rear Seal MERCRUISER ENGINE-5B-23 MAIN BEARINGS CHECKING CLEARANCE To obtain most accurate results, use Plastigage (or equivalent). Plastigage is a wax-like material which compresses evenly between bearing and journal surfaces without damaging either surface. With engine upside-down, crankshaft rests on upper bearings and total clearance can be measured between lower bearing and journal. NOTE: To assure proper seating of crankshaft, all bearing cap bolts should be accurately torqued. In addition, before checking bearing fit, wipe surface of crankshaft journal and bearing clean of oil. 1. With oil pan and oil pump removed, and starting with rear main bearing, remove bearing cap and wipe oil from journal and bearing cap. 2. Place a piece of gauging plastic the full width of bearing (parallel to crankshaft) on journal. (Figure 1) 3. Install bearing cap and evenly torque retaining bolts to specifications. CAUTION: DO NOT turn crankshaft with gauging plastic installed. 4. Remove bearing cap. Flattened gauging plastic will adhere to either bearing shell or journal. 5. Graduated scale on edge of gauging plastic envelope is correlated in thousandths of an inch. Without removing gauging plastic, measure its compressed width (at widest point) with graduations on gauging plastic envelope. (Figure 2) Figure 1. Gauging Plastic on Journal 5B-24 - MERCRUISER ENGINE NOTE: Normally, main bearing journals wear evenly and are not out-of-round. However, if a bearing is being fitter to an out-of-round journal (.001" [,025mm] max.), be sure to fit to maximum diameter of journal. If bearing is fitted to minimum diameter and journal is out-of-round .001", interference between bearing and journal will result in rapid bearing failure. If flattened gauging plastic tapers toward middle or ends, there is a difference in clearance which indicates taper, low spot or other irregularity of bearing or journal. Be sure to measure journal with a micrometer if flattened gauging plastic indicates more than .001 "difference. Figure 2. Measuring Gauging Plastic 6. If bearing clearance is within specifications, bearing insert is satisfactory. If clearance is not within specifications, replace insert. Always replace both upper and lower insert as a unit. NOTE: If a new bearing cap is being installed and clearance is less than .001". inspect for burrs or nicks. If none is found, then install shims as required. 7. A standard .001" or .002" [.025 or .05mm] undersize bearing may produce proper clearance. If not, regrind crankshaft journal for use with next undersize bearing. 8. Proceed to next bearing. After all bearings have been checked, rotate crankshaft to see that there is no excessive drag. 9. Measure crankshaft end play with a dial indicator as outlined in crankshaft section (see "Specifications"). 10. Install new rear main bearing oil seal in cylinder block and main bearing cap. REPLACEMENT 1. Remove and inspect crankshaft. 2. Remove main bearings from cylinder block and main bearing caps. 3. Coat bearing surfaces of new, correct size, main bearings CONNECTING Connecting rod bearings are precision insert tvpe and do not utilize shims for adjustment. DO NOT FILE RODS OR ROD CAPS. If clearances are found to be excessive, a new bearing will be required. Bearings are available in standard size and .001" and .002" (.025 and ,05mm) undersize for new and used standard size crankshafts, and in .010" and .020" (.254 and ,51mm) undersize for reconditioned crankshafts. CHECKING CLEARANCE and REPLACEMENT with oil and install in cylinder block and main bearing caps. 4. Install crankshaft. ROD BEARINGS a. Place a piece of gauging plastic the full width of crankpin (parallel to crankshaft). (Figure 3) b. Install bearing in connecting rod and cap. c. Install bearing cap and torque nuts evenly to specifications. CAUTION: Do not turn crankshaft with gauging plastic installed. 1. With oil pan and oil pump removed, remove connecting rod cap and bearing. 2. Inspect bearing for evidence of wear or damage. Do not reinstall defective bearings. 3. Wipe bearings and crankpin clean of oil. 4. Measure crankpin for out-of-round or taper with a micrometer. If not within specifications, replace or recondition crankshaft. If within specifications and a new bearing is to be installed, measure maximum diameter of crankpin to determine new bearing size required. 5. If within specifications, measure new or used bearing clearances with Plastigage or equivalent. 01634 Figure 3. Plastigage on Crankpin NOTE: If a bearing is being fitted to an out-of-round crankpin, be sure to fit to maximum diameter of crankpin. If bearing is fitted to minimum diameter, and crankpin is out-of-round .001" (,025mm), interference between bearing and crankpin will result in rapid bearing failure. d. Remove bearing cap and. using scale on gauging plastic envelope, measure gauging plastic width at widest point. (Figure 4) 6. If clearance exceeds specifications, select a new, correct size bearing and remeasure clearance. 7. Coat bearing surface with oil, install rod cap and torque nuts to specifications. 8. When all connecting rod bearings have been installed, tap each rod lightly (parallel to crankpin) to assure clearance. 9. Measure all connecting rod side clearances (see specifications in Section 8) between connecting rod cap(s). NOTE: Refer to "Piston Assembly -Installation" (see "Index"). 977 R1 MERCRUISER ENGINE - 5A-25 Overlay Overlay MAIN and CONNECTING ROD BEARING INSERTS CLEANING INSPECTION Clean bearing inserts and caps thoroughly in solvent and dry Inspect each bearing carefully. Replace bearings with scored, with compressed air. DO NOT scrape gum or varnidi deposits chipped or worn surface. Typical examples of unsatisfactory from bearing shells. bearings and causes are shown in Figure 5. Check clearance of used and new bearings with Plastigage. Sections IMPROPER SEATING Dirt Wiped Out Imbedded SCRATCHED into LACK OF OIL BY DIRT Bearing TAPERED JOURNAL RADIUS RIDE FATIGUE FAILURE Figure 5. Typical Bearing Failures 5B-26 - MERCRUISER ENGINE TORSIONAL DAMPER REMOVAL INSTALLATION Figure 1. Removing Crankshaft Vibration Damper 1. Remove alternator belt. CAUTION: Inertia weight section of torsional damper 2. Remove pulley by removing 3 attaching bolts. is assembled to hub with a rubber type material. 3. Remove torsional damper retaining bolt. Installation procedures (with proper tool) must be 4. Install Tool T58P-6316A and T62F-6316B and pull off followed, or movement of inertia weight section on torsional damper. (Figure 1) hub will destroy tuning of torsional damper. 1. Pull torsional damper onto crankshaft with tool T52L-6306-AEE. (Figure 2) 2. Install retaining bolt and washer. Torque to specifications. 3. Install pulley and alternator belt. Tool-T52L-6306-AEE CLEANING 1. Clean oil seal contact surface on crankshaft damper or sleeve with solvent to remove any corrosion, sludge or varnish deposits. Excess deposits, that are not readily- removed with solvent, may be removed with crocus cloth. 2. Use crocus cloth to remove any sharp edges or burrs which might damage the oil seal during installation or cause premature seal wear. DO NOT use crocus cloth to polish seal surface. A finely polished surface may produce poor sealing or cause premature seal wear. INSPECTION Inspect crankshaft damper or sleeve oil seal surface for nicks. sharp edges or burrs that might damage oil seal during installation or cause premature seal wear. Figure 2. Installing Crankshaft Vibration Damper CYLINDER BLOCK FRONT COVER and FRONT SEAL REMOVAL assembly. Transfer water pump to new cylinder block front cover, if cover is being replaced. 1. Drain water and oil from engine. 9. Discard cylinder block front cover gasket. 2. Remove oil pan as outlined. 3. Remove alternator adjustment bracket. FRONT OIL SEAL REPLACEMENT 4. Remove alternator and seawater pump as an assembly by removing mounting bracket from cylinder block front 1. Drive out old seal with a pin-punch. Clean out recess in cover. cover. 3. Remove circulating water pump pulle\ and drive belt. 2. Coat new seal with grease, then install seal in cover. Drive 6. Remove torsional clamper as outlined. sea) in until fully seated in recess. (Figure 3) Check seal 7. Remove fuel filter and fuel pump. after installation to be sure that spring is properly 8. Remove cylinder block front cover and water pump as an positioned in seal. 977 R1 MERCRUISER ENGINE - 5A-27 6. Coat threads of attaching screws with Perfect Seal (C-92-34227) and install screws. Torque cover-to-block attaching screws to specifications. Remove pilot. 7. Apply Multipurpose Lubricant (C-9249588 o C-92-63250) to oil seal lip and vibration damper oil set rubbing surface to prevent damage to seal. 8. Line up crankshaft vibration damper keyway with key on crankshaft. Install vibration damper on crankshaft. 9. Install oil pan as outlined, preceding. 10. Install fuel pump, using a new gasket. Connect fuel pump outlet line. 11. Install water pump pulley, drive belt and spacer. 12. Install alternator adjustment bracket. 13. Install alternator, seawater pump and mounting bracket. Install drive belts. 14. Operate engine and check for leaks. Figure 3. Installing Crankshaft Front Oil Seal INSTALLATION 1. Clean all gasket surfaces. 2. Lubricate timing chain with engine oil. 3. Coat gasket surfaces of block and cover with Perfect Seal (C-92-34227) and position new gasket on block. 4. Position cylinder front cover on cylinder block. Use care when installing cover to avoid seal damage or possible gasket mislocation. 5. Install cylinder front cover to seal alignment tool into proper position. (Figure 4) TIMING CHAIN, SPROCKETS and FUEL PUMP ECCENTRIC REMOVAL 3. Replace all components of timing chain and sprocket assembly if any one item needs replacement. 1. Drain cooling system and crankcase. 2. Remove cylinder block front cover and water pump as an assembly. FUEL PUMP ECCENTRIC 3. Slide off crankshaft front oil slinger. CLEANING 4. Check timing chain deflection. Refer to "Timing Chain Deflection", following. Clean fuel pump eccentric in solvent and dry with compressed 5. Crank engine until timing marks on sprockets are posi-air. tioned as shown in Figure 7. INSPECTION 6. Remove crankshaft sprocket cap screw, washers and fuel pump eccentric. Slide both sprockets and timing chain Inspect fuel pump drive eccentric for scores, nicks and forward and remove as an assembly. excessive wear. Replace eccentric if scored. TIMING CHAIN and SPROCKETS TIMING CHAIN DEFLECTION CLEANING 1. Rotate crankshaft in clockwise direction (as viewed from 1. Clean all parts in solvent and dry with compressed air. front) to take up slack on left side of chain. 2. Lubricate timing chain with engine oil before installing on 2. Establish a reference point on cylinder block and measure engine. from this point to chain (Figure 5) INSPECTION 3. Rotate crankshaft in opposite direction to take up slack on 1. Inspect chain for broken links. right side of chain. Force left side of chain out with fingers 2. Inspect sprockets for cracks, scores, nicks and worn or and measure distance between reference point and chain. damaged teeth. The deflection is difference between the 2 measurements. 5C-28 - MERCRUISER ENGINE 977 R1 If deflection exceeds specifications, replace timing chain 6) Be sure that timing marks on sprockets are positioned as and sprockets. shown in Figure 7. INSTALLATION 2. Install fuel pump eccentric, washers and camshaft sprocket cap screw. Torque cap screw to specifications and install 1. Position sprockets and timing chain on camshaft. (Figure crankshaft oil slinger. (Figure 8) Reference Point Right Side of Chain Take Up Slack on LeftSide; Establish Reference Point. Measure Distance "A". Take Up Slack on Right Side. Force Left Side Out. Measure Distance "B". Deflection Is "A " Minus "B". 06046 Timing Mark:. 06043 A Figure 6. v Removing or Installing Timing Chain 06045 Dowel Crankshaft Front Oil Slinger 977 R1 MERCRUISER ENGINE - 5A-29 CAMSHAFT Camshaft and related parts are shown in Figure 1. REMOVAL 1. Drain cooling system and crankcase. 2. Remove cylinder front cover and timing chain, following procedure under "Cylinder Front Cover and Timing Chain Removal", preceding. 3. Disconnect coil high tension wire from coil and spark plug wires from spark plugs. Remove distributor cap and spark plug wires as an assembly. 4. Disconnect distributor wire from coil. 5. Remove distributor hold-down bolt and clamp and remove distributor. 6. Remove intake manifold as described previously. 7. Remove valve mechanism as outlined, preceding. 8. Remove hydraulic lifters. 9. Remove fuel pump eccentric and sprockets. 10. Remove camshaft thrust plate. Carefully remove camshaft by pulling toward front of engine. Use caution to avoid damaging camshaft bearings. CLEANING and INSPECTION 1. Clean camshaft in solvent and dry with compressed air. 2. Inspect camshaft lobes for scoring and signs of abnormal wear. Lobe wear characteristics may result in pitting in general area of lobe toe. This pitting is not detrimental to operation of camshaft, therefore, do not replace camshaft until lobe lift loss has exceeded .005" (.13mm). 3. Check lift of camshaft lobes with camshaft installed in engine or on "V " blocks. Refer to "Camshaft Lobe Lift" (see "Index"). 4. Check distributor drive gear for broken or chipped teeth. 5. Remove light scuffs, scores or nicks from camshaft machined surfaces with a smooth oil stone. INSTALLATION 1. Oil camshaft journals and apply Lubriplate to lobes. Carefully slide camshaft thru bearings. Install camshaft thrust plate with groove toward cylinder block. Check camshaft end play (see "Index"). 2. Install lifters and valve mechanism as outlined. 3. Install intake manifold and related parts as outlined. 4. Replace crankshaft front oil seal. Install timing chain, cylinder front cover and related parts. 5. With No. 1 piston TDC at end of compression stroke, position distributor in block with rotor at No. 1 firing position and points open. Install hold-down clamp. 6. Check valve clearance as outlined. 7. Install rocker arm covers as described previously. 8. Clean and install crankcase ventilation system. 9. Connect ignition coil wires. 10. Install distributor cap and plug wires. Connect high tension lead at coil. 11. Fill crankcase with proper engine oil. 12. Start engine and check and adjust ignition timing. 13. Operate engine at fast idle and check all hose connections and gaskets for leaks. When engine temperature has stabilized, adjust engine idle speed and idle fuel mixture. Fuel Pump Eccentric 06047 CAMSHAFT BEARING REPLACEMENT Camshaft bearings are available pre-finished to size for standard journal diameters. Bearings art- not interchangeable from one bore to another. 1. Remove camshaft, flvwheel and crankshaft, following 2.3. appropriate procedures. Push pistons to top of cylinders. Remove camshaft rear bearing bore plug. Remove camshaft bearings with Tool T65L-6250-A. (Figure 2) Select proper size expanding collet and back-up nut and assemble on expanding mandrel. With expanding collet 5C-30 MERCRUISER ENGINE 977 R1 collapsed, install collet assembly in camshaft bearing and shown and install on expanding mandrel. Wrap a cloth tighten back-up nut on expanding mandrel until collet fits around threads of puller screw to protect front bearing or camshaft bearing. journal. Tighten pulling nut against thrust bearing and pulling plate to remove camshaft bearing. Be sure to hold a !\OTE: Camshaft bearing diameters vary. Replacement wrench on end of puller screw to prevent screw from bearings are numbered according to location in cylinder turning. block. No. I bearing is at front of block. 5. Repeat procedure for each bearing. To remove front 4. Assemble puller screw and extension (if necessary) as bearing, install puller screw from rear of cylinder block. Expanding Collet Position new bearings crankshaft, flywheel Puller Screw Extension Pulling Plate and related parts, fol- Tool -T65L-6250-A lowing appropriate procedures. 06049 Figure 2. Camshaft Bearing Replacement Thrust Bearing 7. at bearing bores with oil holes aligned and press in place with tool shown in Figure 2. Be sure to center pulling plate and puller screw to avoid damage to bearing. Failure to use correct expanding col- let can cause severe bearing damage. Be sure that front bearing is installed .005" to .020" (.13 to ,51mm) below front face of cylinder block. (Figure 3> Install core plug. (Figure 4) Instal l camshaft, Figure 3. Camshaft Front Bearing Measurement Figure 4. Installing Camshaft Bearing Plug CAMSHAFT LOBE LIFT Check lilt of each lobe in consecutive order and make a note adaptor for ball-end push rods. of readings. 3. Be sure that push rod is in valve lifter socket. Install dial indicator so that ball socket adaptor of indicator is on end 1. Remove valve rocker arm cover(s). of push rod and in same plane as push rod movement. 2. Remove rocker arm stud nut. ball unit and rocker arm. Use (Figure 5) MERCRUISER ENGINE -5B-31 4. Disconnect ignition coil. 5. Slowly turn crankshaft over until lappet or lifter is on low- side of camshaft lobe. At this point, push rod will be in its lowest position. IMPORTANT: An incorrect reading will be taken if hydraulic lifters have not had sufficient time to bleed down. Lifters may be manually bled down to ensure an accurate reading. 6. Zero the dial indicator. Continue to rotate crankshaft slowly until push rod is in fully-raised position (highest indicator reading). 7. Compare total lift (recorded on indicator) with specifications. 8. To check accuracy of original indicator reading, continue to rotate crankshaft until indicator reads zero. If lift on any lobe is below specified wear limits, replace camshaft and valve lifters operating on worn lobe(s). IMPORTANT: Do not rotate crankshaft until hydraulic valve lifters have had sufficient time to bleed down. Manually bleeding down will reduce time requirement. To do otherwise may cause serious valve damage. 9. Remove dial indicator and auxiliary starter switch. 10. Lubricate rocker arm and ball unit with engine oil and CAMSHAFT END PLAY 1. Sprocket can break or become damaged by prying against aluminum-nvlon camshaft sprocket with valve train load on camshaft. Rocker arm adjusting nuts, therefore, must be backed off sufficiently to free camshaft. After checking camshaft end play, adjust valve clearance. 2. Push camshaft toward rear of engine. Install dial indicator so that indicator point is on camshaft sprocket attaching screw (Figure 6) or gear hub. Zero dial indicator. Position a large screwdriver between camshaft sprocket or gear and block. Pull camshaft forward and release it. 3. Compare dial indicator reading with specifications. If end play is excessive, replace thrust plate. If a spacer is used, check spacer for correct installation before it is removed. If spacer is correctly installed, replace thrust plate. 4. Remove dial indicator. Figure 6. Checking Camshaft End Play - V-8 Engine CYLINDER BLOCK lint-free cloth. Finally, wipe bore(s) with a clean clot CLEANING dipped in engine oil. If these procedures are ignored, I. After au\ cylinder bore repair operation, such as honing or cylinder bore(s) may rust. deglazing, clean bore(s) willi soap or detergent and water. 2. If engine is disassembled, thoroughly clean block with Then, thoroughly rinse bore(s) with clean w ater to remove solvent. Remove old gasket material from all machined soap or detergent and wipe bore(s) drv with a clean. surfaces. Remove all pipe plugs that seal oil passages, then 5C-32 - MERCRUISER ENGINE 977 R1 Figure 5. Testing Camshaft Lobe Lift Stud Mounted Rocker Arms secure them in position with stud nut. 11. Install valve rocker arm cover(s). clean all passages. Blow out all passages, bolt holes, etc, with compressed air. 3. Be sure that threads in cylinder head bolt holes are clean. Dirt in threads may cause binding and result in a false torque reading. Use a tap to true-up threads and to remove any deposits. 4. Thoroughly clean grooves in crankshaft bearing and bearing retainers. INSPECTION 1. After thoroughly cleaning block, check for cracks. Minute cracks (not visible to naked eye) may be detected by coating suspected area with mixture of 25% kerosene and 75% light engine oil. Wipe part dry and immediately apply coating of zinc oxide dissolved in wood alcohol. If cracks are present, coating will become discolored at defective area. Replace block, if it is cracked. 2. Check all machined gasket surfaces for burrs, nicks, scratches and scores. Remove minor imperfections with an oil stone. 3. Check cylinder block for flatness of cylinder head gasket surface following procedure and specifications recommended for cylinder head. Cylinder block can be machined to bring cylinder head gasket surface within flatness specifications, but not to exceed .010" (.254mm). 4. Replace all expansion-type plugs with evidence of leakage. 5. Inspect cylinder walls for scoring, roughness or other signs of wear. Check cylinder bore for out-of-round and taper. Measure bore with an accurate bore gauge, following instructions of the manufacturer. Measure diameter of each cylinder bore at top, middle and bottom with gauge placed at right angles and parallel to center line of engine. (Figure 7) Use only measurements obtained at 90° to engine centerline when calculating piston to cylinder bore clearance. "A " = At right angle to ••— .snub list or tN&tNi— centerline of engine "B " = Parallel to centerline of engine "Out-of-round" = Difference between "A" and "B" "Taper" = Difference between measurement at top of cylinder bore and "A " measurement at bottom yj of cylinder bore. Figure 7. Cylinder Bore Out-of-Round and Taper 6. Refinish cylinders which are deeply scored and/or when out-of-round and/or taper exceeds wear limits. 7. If cylinder walls have minor surface imperfections, but out-of-round and taper are within limits, it may be possible to remove imperfections by honing cylinder walls and installing new service piston rings, if piston clearance is within specified limits. REFINISHING CYLINDER WALLS I. Honing is recommended for refinishing cylinder walls only when walls have minor scuffs or scratches, or for fitting pistons to specified clearance. The grade of hone is determined by amount of metal to be removed. Follow instructions of hone manufacturer. If coarse stones are used to start honing operation, leave enough material so that all hone marks can be removed with finishing hone which is used to obtain proper piston clearance. 2. Refinish cylinder walls that are severely marred and/or worn beyond specified limits. Before any cylinder is refinished, all main bearing caps must be in place and tightened to proper torque so that crankshaft bearing bores will not become distorted from refinishing operation. 3. Refinish only damaged cylinder or cylinders. All pistons are same weight, both standard and oversize, therefore, various piston sizes can be used without upsetting engine balance. 4. To determine maximum oversize, refinish cylinder with most wear first. If cylinder will not clean up when refinished for maximum oversize piston, replace block. 5. Refinish cylinder to within approximately .0015" (.038mm) of required oversized diameter. This will allow enough stock for final step of honing so that correct surface finish and pattern are obtained. 6. For proper use of refinishing equipment, follow instructions of manufacturer. Only experienced personnel should perform this work. 7. Use a motor-driven, spring-pressure-type hone at a speed of 300-500 RPM. Hones of grit sizes 180-220 normally will provide desired bore surface. When honing cylinder bores, use a lubricant mixture of equal parts of kerosene and SAE No. 20 motor oil. Operate hone to produce a cross-hatch finish on cylinder. bore. Cross-hatch pattern should be at an angle of approximately 30° to cylinder bore. 8. After final operation in either of 2 refinishing methods described, and prior to checking piston fit, thoroughly clean and oil cylinder walls. 9. Check piston fit following procedure in this section. Mark pistons to correspond to cylinders for reinstallation. When cylinder refinishing has been completed and all pistons are filled, thoroughly clean entire block and oil cylinder walls following procedure under "Cylinder Block Cleaning", preceding. FITTING PISTONS 1. Pistons are available for service in standard sizes and .003" and .020"(.076 and ,508mm) oversizes. 2. Measure pislon OD and cylinder bore. Dimensions should be within specifications, and piston to bore clearance (bore ID minus piston OD) must be within specified limits. 3. If clearance is greater than maximum limit, recheck calculations to be sure that proper-size piston has been selected or check for a damaged piston, then try a new piston. 4. If clearance is less than minimum limit, recheck calculations before trying another piston. If none can be fitted, refinish cylinder to provide correct piston clearance. NOTE: When a piston has been fitted, mark it for assembly in cylinder to which it was fitted. 5. If taper, out-of-round and piston-to-cylinder-bore clearance conditions of cylinder bore are within specified limits, new piston rings will give satisfactory service. 6. If installing new rings in a used cylinder, that has not been refinished, remove cylinder wall glaze (refer to "Cylinder Block, Refinishing Cylinder Walls", preceding). Be sure to clean cylinder bore thoroughly. 977R1 MERCRUISER ENGINE - 5C-33 TO FIT A PISTON .... centerline of piston pin and at 90° to piston pin axis. 3. Make sure that piston and cylinder block are at room 1. Calculate size piston required by taking a cylinder bore temperature (70° F). After any refinishing operation, check. allow cylinder bore to cool and make sure that piston and 2. Select proper size piston to provide desired clearance (refer to specifications). Measure piston diameter in line with bore are clean and dry before piston fit is checked. REPAIRING CYLINDER BLOCK 1. Porosity or sand hole(s), which cause oil seepage or leakage, can occur with modern casting processes. Make complete inspection of engine and transmission. If leak is attributed to porous condition of cylinder block or sand hole(s), make repairs with metallic plastic. DO NOT repair cracks with this material. Confine repairs to those cast iron engine component surfaces (Figure 8) where inner wall surface is not exposed to engine coolant pressure or oil pressure, for example: a. Cylinder block surfaces extending along length of block upward from oil pan rail to cylinder water jacket but not including machined areas. b. Lower rear face of cylinder block. c. Intake manifold casting. Repairs are not recommended to intake manifold exhaust crossover section, since temperatures can exceed recommended temperature limit of 500° F (272°C). d. Cylinder front cover on engines using cast iron material. e. Cylinder head, along rocker arm cover gasket surface. 2. Use following procedure to repair porous areas or sand holes in cast iron. a. Clean surface to be repaired by grinding or rotary filing to a clean bright metal surface. Chamfer or undercut hole or porosity to a greater depth than rest of cleaned surface. Solid metal must surround hole. Openings larger than J4" (6.35mm) should not be repaired with metallic plastic. Openings in excess of can be drilled, tapped and plugged with common tools. Clean repair area thoroughly . Metallic plastic will not stick to a dirty or oil surface. b. Mix metallic plastic base and hardener as directed on container. Stir thoroughly until uniform. c. Apply repair mixture with a suitable clean tool (puttyknife, wood spoon, etc), forcing epoxy into hole or porosity. FRONT and LEFTSIDE TYPICAL FOR V-8 ENGINE 06106 REAR and RIGHTSIDE Figure 8. Typical Cast Iron Cylinder Block Areas Repairable with Metallic Plastic d. Allow repair mixture to harden by one of 2 methods: Heal cure with a 250° watt lamp placed 10" (25.4cm) from the repaired surface, or air dry for 10-12 hours at temperatures above 50° F (10°C). e. Sand or grind repaired area to blend with general contour of surrounding surface. f. Paint surface to match rest of block. CORE PLUG REPLACEMENT REMOVAL 5. Coat plug and/or bore lightly with Perfect Seal (C-92-34227) and install per following procedure. 1. To remove a large core plug, drill a Vz" (12.7mm) hole in center of plug and pry it out with a large, drift punch. INSTALLATION 2. On a small core plug, drill a 54" (6.35mm) hole in center of plug and pry it out with a small pin punch. Clean and 1. Install core plugs (Figure 9) with flanged edge out. inspect plug bore. Maximum diameter of this plug is located at outer (sealing) 3. Prior to installing a core plug, inspect plug bore for any edge of flange. damage that would interfere with proper sealing of plug. If bore is damaged, it is necessary to true surface by boring for next specified oversize plug. IMPORTANT: Install plug into machined bore only with a 4. Oversize (OS) plugs are identified by OS stamped in flat properly designed tool. Under no circumstances is plug to located on cup side of plug. be driven into bore with a tool that contacts flange. This 977 R1 5C-34 - MERCRUISER ENGINE method will damage sealing edge and result in leakage Sealing Edge Before Installation and/or plug blow-out. Flanged (trailing) edge must be below chamfered edge of bore to effectively seal the plugged bore. If core plug Cup Type Core replacing tool has a depth seating surface, DO NOT seat Plug Replacer Tool the tool against a non-machined (casting) surface. Figure 9. Core/Plug Replacement I MERCRUISER ENGINE -5B-35 SECTION 5 - ENGINE PART C - ENGINE MECHANICAL, V-8 GM A BRUNSWICK COMPANY Engine Mechanical • V-8 GM EnginesToolsGeneralRocker Arm Cover Removal Installation Exhaust Manifolds Removal Cleaning and Inspection Installation Intake Manifold Removal Cleaning and Inspection Installation Valve Mechanism Removal Installation Adjustment Valve Adjustment - Engine Stopped Valve Adjustment - Engine Running Hydraulic Valve Lifters Locating Noisy Lifters Removal Disassembly Cleaning and Inspection Reassembly Installation Valve Stem Oil Seal and/or Valve Spring Removal Reassembly Cylinder Head Removal Cleaning and Inspection Installation Cylinder Head and Valve ConditioningDisassemblyCleaningInspectionRocker Arm Studsand Push Rod Guides-RepairsValve Guide Bore RepairValve Seat RepairValve RepairReassembly Oil Pan Removal Installation Oil Pump Removal Disassembly Cleaning and Inspection Reassembly Installation Torsional Damper Removal Installation INDEX Page 5C-1 5C-1 5C-1 5C-1 5C-1 5C-1 5C-2 5C-2 5C-2 5C-2 5C-3 5C-3 5C-3 5C-3 5C-4 5C-4 5C-4 5C-4 5C-4 5C-4 5C-5 5C-5 5C-6 5C-6 5C-6 5C-6 5C-7 5C-7 5C-7 5C-7 5C-8 5C-8 5C-8 5C-8 5C-8 5C-8 5C-8 5C-9 .5C-9 5C-10 5C-10 5C-10 5C-11 5C-12 5C-12 5C-12 5C-12 5C-12 5C-12 5C-12 5C-13 5C-13 5C-13 5C-13 5C-13 Crankcase Front Cover 5C-14 Removal 5C-14 Installation 5C-14 Oil Seal Replacement 5C-14 With Cover Removed 5C-14 Without Cover Removed 5C-14 Flywheel 5C-15 Removal 5C-15 Installation 5C-15 Oil Seal (Rear Main) 5C-15 Replacement 5C-15 Main Bearings 5C-16 Inspection 5C-16 Checking Clearance 5C-16 Replacement 5C-17 With Crankshaft Removed 5C-17 Without Crankshaft Removed 5C-17 Connecting Rod Bearings 5C-18 Inspection and Replacement 5C-18 Connecting Rod and Piston Assembly 5C-19 Removal 5C-19 Disassembly 5C-19 Piston Support Tool 5C-19 Cleaning and Inspection 5C-20 Connecting Rods 5C-20 Pistons 5C-20 Piston Pins 5C-20 Piston Rings 5C-20 Reassembly 5C-21 Installation 5C-23 Crankshaft 5C-23 Removal 5C-23 Cleaning and Inspection 5C-23 Installation 5C-24 Timing Chain and/or Sprockets 5C-25 Removal 5C-25 Installation 5C-25 Camshaft 5C-25 Measuring Lobe Lift 5C-25 Removal 5C-25 Inspection 5C-26 Installation 5C-26 Crankshaft Sprockets 5C-26 Removal 5C-26 Installation 5C-26 Camshaft Bearings 5C-27 Removal 5C-27 Inspection 5C-27 Installation 5C-27 Cylinder Block 5C-28 Cleaning and Inspection 5C-28 Repairs Cylinder Conditioning 5C-28 Cylinder Boring 5C-28 Cylinder Honing 5C-28 Piston Selection 5C-29 ENGINE MECHANICAL -V-8GM ENGINES TOOLS All "J-" (Special) Tools Listed in This Section May Be Purchased from: Kent-Moore, Inc. 28635 Mound Road Warren, Mich. 48089 GENERAL MOTE: This section contains information for 305, 350 and camshaft, drives the oil pump. Main oil gallery feeds oil thru 454 cubic inch displacement (CID) "GM" type MerCruiser drilled passages to camshaft and crankshaft to lubricate Engines. While photos may not be exactly like all represented bearings. Valve lifter oil gallery feeds valve lifters, which, thru models, they are technically applicable as indicated. hollow push rods, feed individually mounted rocker arms. Crankshaft has 5 main bearings and camshaft has 5 bearings. Design of boat and particular repair procedure may require that engine be removed from boat. Engine Full pressure lubrication thru oil filter is furnished by should be placed on engine stand for major repairs. gear-type oil pump. Distributor, driven by a helical gear on ROCKER ARM COVER REMOVAL 3. Remove rocker arm cover. 1. Remove rocker arm cover attaching screws. 2. Disconnect crankcase ventilation hoses. INSTALLATION CAUTION: DO NOT pry rocker arm cover loose. 1. Clean gasket surfaces on cylinder head and rocker arm Gaskets, which adhere to cylinder head and rocker arm cover with degreaser. Install a new gasket with rocker arm cover, may be sheared by bumping end of rocker arm cover and torque to specifications. cover from the rear with palm of hand or a rubber 2. Connect crankcase ventilation hoses. mallet. 3. Start engine and check for leaks. 977R1 MERCRUISER ENGINE • 5C-1 EXHAUST MANIFOLDS 1 - Tube 2 • Pipe Plug 3 - Drain Plug 4 - Exhaust Elbow 5 - Gasket 6 - Water Distribution Housing 7 - Drain Plug 8 - Screw 9 - End Cap 10 - Gasket 11 - Stud 12- Exhaust Manifold 13- Pipe Plug 14-Belt 15 - Drain Plug 16- End Cap 17 - Screw 18 - Gasket 19 - Gasket 20 - Sleeve 21 - Lockwasher 22- Nut Figure 1. Exhaust Manifold Assembly REMOVAL 2. Check manifold for cracks and replace if cracked. 3. Inspect all parts carefully. Machined surfaces must be clean 1. Left (port) manifold and free of all marks or scratches, or water or/and exhaust a. Drain engine cooling system. leaks may result. b. Remove exhaust tube and water hoses from left 4. Check water passages for sand, silt or other foreign manifold. material. c. Remove bolts which secure left exhaust manifold to 5. If further inspection is desired, pipe plugs may be removed cylinder head. from exhaust manifold and exhaust elbow. 2. Right (starboard) manifold a. Drain engine cooling system. INSTALLATION b. Remove exhaust tube and water hoses from right manifold. 1. Using new gaskets, install exhaust manifold to cylinder c. Disconnect fuel lines from water separating fuel filter head. Torque bolts to specifications. and remove fuel filter assembly. d. Remove bolts which secure right exhaust manifold to NOTE: For right manifold installation, install dipstick cylinder head. tube support bracket with proper manifold boll. CLEANING and INSPECTION 2. Install exhaust tubes and water hoses. 3. On right manifold installation, install water separating fuel 1. Clean gasket material from all mating surfaces and wash filter and connect fuel lines. parts in solvent. 4. Run engine and check for leaks. 5C-2 - MERCRUISER ENGINE 977 R1 INTAKE MANIFOLD 1 - Intake Manifold 2 - Connector 3 - Clamp 4- Hose 5 • Stud 6 - Guard 7 - Lockwasher 8 - Screw 9 - Lifting Eye 10-Pipe Plugs 11 - Screw 12- Washer 13 - Gaskets Figure 2. Intake Manifold Assembly and Related Parts REMOVAL 1. Drain engine cooling system. 2. Disconnect crankcase ventilating hoses and water hoses. 3. Disconnect carburetor linkage and fuel line. 4. Disconnect distributor to switch box wires and distributor ground wire. 5. Remove distributor cap and mark rotor position with chalk. Also mark distributor position in intake manifold, then remove distributor. 6. Disconnect wire from water temperature sending unit. 7. Remove manifold attaching bolts, then remove manifold and carburetor as an assembly. NOTE: If manifold is to be replaced, transfer carburetor and other related parts to new manifold. CLEANING and INSPECTION 1. Clean gasket material from all mating surfaces. CAUTION: When cleaning cylinder head mating surface, do not allow gasket material to enter engine crankcase. 2. Inspect manifold for cracks or scratches. Machined sur-Figure 3A. Intake Manifold Torque Sequence - 454 CID faces must be clean and free of all marks, or deep scratches Models or leaks may result. 3. Check intake passages for varnish buildup or other foreign 3. Install distributor, positioning distributor housing and material. Clean as necessary. rotor to aline with chalk marks, then install distributor cap. INSTALLATION 4. Connect distributor wires to switch box and ground. 1. Install manifold gaskets on cylinder block and cylinder 5. Connect fuel line and carburetor linkage. heads. Use Perfect Seal (C-92-34227) at water passages and 6. Connect water temperature sending unit wire. where gaskets butt together. 7. Connect crankcase ventilating hoses and water hoses. 2. Carefully install manifold assembly and torque bolts to 8. Start engine; adjust ignition timing and carburetor idle specifications in sequence outlined in Figure 3 or 3A. speed and mixture. Check for leaks. Figure 3. Intake Manifold Torque Sequence - 305 and 350 CID Models 977R1 MERCRUISER ENGINE - 5C-3 VALVE MECHANISM 1 - Valve Locks 2 - Cap (Exhaust Valve Rotator on Some Models) 3 - Valve Spring 4 - Seal 5 - Shim 6 - Spacer 7 - Valve Figure 4. Valve Mechanism and Related Parts REMOVAL 1. Remove rocker arm covers as outlined. 2. Remove rocker arm nuts, rocker arm balls, rocker arms and push rods. NOTE: Place rocker arms, rocker arm balls and posh rods in a rack for reinstallation in the same locations. INSTALLATION NOTE: When installing new rocker arms and/or rocker arm balls, coat bearing surfaces of rocker arms and rocker arm balls with engine oil. 1. Install push rods. Be sure push rods seat in lifter socket. 2. Install rocker arms, rocker arm balls and rocker arm nuts. Tighten rocker arm nuts until all lash is eliminated. ADJUSTMENT Valve lash can be adjusted either with engine stopped or running. See following procedures. 1. VALVE ADJUSTMENT - ENGINE STOPPED With valve cover removed, adjust valves when lifter is on low- part of camshaft lobe,as follows: a. Crank engine with starter or turn over in normal direction of rotation until mark on torsional damper lines up with center "0 " mark on timing tab fastened to crankcase front cover, and engine is in No. 1 firing position. This may be determined by placing fingers on No. 1 valve as mark on damper comes near "0 " mark on timing mark. If valves move as mark comes up to timing tab, engine is in No. 6 firing position and should be turned over one more time to reach No. 1 position. b. With engine in No. 1 firing position as determined above, the following valves may be adjusted. Left Hand (Standard) Rotation Engines Exhaust - 1-3-4-8 Intake - 1-2-5-7 Right Hand (Opposite) Rotation Engines Exhaust - 1-2-5-7 Intake - 1-3-4-8 5C-4 - MERCRUISER ENGINE C. Back out adjusting nut until lash is felt at push rod, then turn in adjusting nut until all lash is removed. This can be determined by moving push rod up-anddown while turning adjusting nut until all play is removed. (Figure 5) Figure 5. Valve Adjustment - Engine Stopped Hydraulic lifters now can be adjusted by tightening adjustment nut an additional %-turn to place plunger in center of its travel. No other adjustment is required. d. Crank engine one revolution until pointer "0 " mark and torsional damper mark are again in alignment. This is No. 6 firing position. With engine in this position, the following valves may be adjusted as previously outlined. Left Hand (Standard) Rotation Engines Exhaust - 2-5-6-7 Intake -3-4-6-8 Right Hand (Opposite) Rotation Engines Exhaust - 3-4-6-8 Intake -2-5-6-7 e. Install rocker arm covers as outlined. f. Adjust carburetor idle speed and mixture. 2. VALVE ADJUSTMENT - ENGINE RUNNING Following procedure is performed with engine running: a. After engine has been rechecked for normal operating temperature, remove valve covers and install a reworked valve cover (cut top out of a used valve cover) and gasket on cylinder heads to prevent oil from running out. (Figure 6) b. With engine running at idle, back valve rocker arm nuts off (one at a time) until valve rocker arm starts to clatter. c. Turn rocker arm nut down until clatter just stops. This is zero lash position. d. Turn nut down V4 additional turn and pause 10 seconds until engine runs smoothly. Repeat additional VA turns, pausing 10 seconds each time, until nut has been turned down %-tum from the zero lash position. 977R1 e. Repeat Steps b-c-d to adjust other valves. Remove reworked valve covers and install new gaskets and covers. f. Adjust carburetor idle speed and mixture. Figure 6. Valve Adjustment - Engine Running 1 - Lifter Body 5 - Check Ball Retainer b. In rare cases, ball itself may be out-of-round or have a 2 - Push Rod Seat 6 - Push Rod Seat Retainer flat spot. 3 - Metering Valve (Lifter A) 7 - Plunger c. Improper adjustment Inertia Valve (Lifter B) 8 - Check Ball Spring 4 - Check Ball 9 - Plunger Spring In most cases, where noise exists in one or more lifters, all lifter units should be removed, disassembled, cleaned in Figure 7. Hydraulic Valve Lifters NOTE: This 3A-turnslowly to allow lifterpossibility of interferenceof piston which mightbent push rods. " 04982 HYDRAULIC VALVE Hvdraulic valve lifters require little attention. Lifters are extremely simple in design, readjustments are not necessary and servicing requires only that care and cleanliness be exercised in the handling of parts. Parts identification is shown in Figure 7. LOCATING NOISY LIFTERS Locate a noisy valve lifter by using a piece of garden hose approximately 4 ft. (1.2m) in length. Place one end of hose near end of each intake and exhaust valve, with other end of hose to the ear. In this manner, sound is localized, making it easy to determine which lifter is at fault. Another method is to place a finger on face of valve spring retainer. If lifter is not functioning properly, a distinct shock will be felt when valve returns to its seat. General types of valve lifter noise are as follows: 1. Hard rapping noise -- Usually caused by plunger becoming tight in bore of lifter body so that return spring cannot push plunger back up to working position. Probable causes are: a. Excessive varnish or carbon deposit, causing abnormal stickiness. b. Galling or "pick-up" between plunger and bore of lifter body, usually caused by an abrasive piece of dirt or metal wedged between plunger and lifter body. 2. Moderate rapping noise - Probable causes are: a. Excessively high leakdown rate. b. Leaky check valve seat. c. Improper adjustment. 3. General noise throughout valve train - This will, in most cases, be a definite indication of insufficient oil supply or improper adjustment. 4. Intermittent clicking - Probable causes are: a. A microscopic piece of dirt momentarily caught between ball seat and check valve ball. LIFTERS LIFTER "A" LIFTER B" preload adjustment must be done to adjust itself, thus preventing between inlet valve head and top result in internal damage and I or 977R1 MERCRUISER ENGINE - 5C-5 solvent, reassembled and reinstalled in engine. If dirt, corrosion, carbon, etc, is shown to exist in one unit, it more likely exists in all the units, thus it would only be a matter of time before all lifters caused trouble. REMOVAL 1. Remove intake manifold as outlined. 2. Remove valve mechanism as outlined. 3. Remove valve lifters. NOTE: Place valve lifters in a rack so that they may be reinstalled in same location. DISASSEMBLY 1. Hold plunger down with a push rod and remove push rod seat retainer with blade of small screwdriver. 2. Remove push rod seat and metering valve (lifter "A") or push rod seat and inertia valve assembly (lifter "B"). (Figure 7) 3. Remove plunger, ball check valve assembly and plunger spring. 4. Remove ball check valve and spring by prying ball retainer loose from plunger with blade of a small screwdriver. (Figure 8) Small Screwdriver 05060 Figure 8. Removing Ball Check Valve CLEANING and INSPECTION Thoroughly clean all parts in cleaning solvent and inspect them carefully. If any parts are damaged or worn, entire lifter assembly should be replaced. If outer lifter body wall is scuffed or worn, inspect cylinder block lifter bore. If bottom of lifter is scuffed or worn, inspect camshaft lobe. If push rod seat is scuffed or worn, inspect push rod. NOTE: Inertia valve and retainer (lifter "B") (Figure 7) should not be removed from push rod seat. To check valve, shake push rod seat and inertia valve assembly. Valve should move. REASSEMBLY 1. Place check ball on small hole in bottom of plunger. 2. Insert check ball spring on seat in ball retainer and place retainer over ball so that spring rests on ball. Carefully Figure 9. Installing Ball Check Valve press retainer into position in plunger with blade of a small screwdriver. (Figure 9) 3. Place plunger spring over ball retainer and slide lifter body over spring and plunger, being careful to line up the oil feed holes on lifter body plunger. 4. Fill assembly with oil, then insert end of a 1/8" drift pin into plunger and press down. At this point, oil holes in lifter bodv and plunger assemblv will be aligned. (Figure 10) CAUTION: Do not attempt to force or pump the plunger. 5. Insert a 1/16" drift pin thru both oil holes to hold plunger down against lifter spring tension. (Figure 10) NOTE: On lifter "B" (Figure 7),drift pin must not extend inside plunger. 6. Remove 1/8" drift pin and refill assembly with oil. 05027 Figure 10. Assembling Hydraulic Lifters 5C-6 - MERCRUISER ENGINE 7. Install metering valve and push rod seat (lifter "A" ) or push rod seat and inertia valve assembly (lifter "B"). (Figure 7) 8. Install push rod seat retainer, press down in push rod seat and remove 1/16'1 drift pin from oil holes. Lifter now is completely assembled, filled with oil and ready for installation. NOTE: Before installing lifters. coat bottom of lifter with engine oil. INSTALLATION \OTE: Whenever valve lifters are being installed, coat bottom of valve lifters with engine oil. 1. Install valve lifters. 2. Install intake manifold as outlined. 3. Install and adjust valve mechanism as outlined. Two types of hydraulic lifters are used. Both types operate on the same principle and are serviced basically in the same manner. Complete lifter assemblies are interchangeable, but parts from one lifter are not interchangeable with another. Both lifters are easily identified by outside configuration of lifter bodv. Identify them as lifter "A" and lifter "B". (Figure 7) VALVE STEM OIL SEAL and/or VALVE SPRING 05043 Figure 11. Valve Assembly Related Parts REMOVAL 1. Remove rocker arm cover as outlined. 2. Remove spark plug, rocker arm and push rod on cylinders) to be serviced. 3. Apply compressed air to spark plug hole to hold valves in place. Figure 12. Air Adaptor Tool NOTE: A tool to apply air to the cylinder is available thru local jobbers, or spark plug may be used. (Be sure to use correct seat-type plug.) Chisel spark plug as shown, then drive porcelain out of plug by tapping center electrode against a hard block. Using a W pipe tap, cut threads in remaining portion of spark plug and assemble as shown. (Figure 12) 977 R1 4. Compress valve spring with J-5892 tool to remove valve locks, valve cap (or rotator) and valve spring and damper. (Figure 13) 5. Remove valve stem oil seal. Tool J-5892 Figure 13. Compressing Valve Spring REASSEMBLY 305/350 CID Models 1. Set valve spring, damper, valve shield and cap in place. Compress spring with Tool J-5892 and install oil seal into lower groove of valve stem. NO TE: A light film of oil will help prevent twisting of the seal. 2. Install valve locks and release pressure of tool, being sure that locks are in place. Grease may be used to help hold locks while removing pressure from tool. 454 CID Models 1. Install new valve stem oil seal (coated with oil) in position over valve guide. 2. Set spacer, valve spring and damper and valve cap in place. 3. Compress spring with J-5892 tool and install valve locks. Then release compressor tool, making sure that locks seat properly in groove of valve stem. NOTE: Crease may be used to hold locks in place while releasing compressor tool. 4. Install spark plug, using a new gasket, and torque to specifications. 5. Install and adjust valve mechanism as outlined. MERCRUISER ENGINE - 5A-7 CYLINDER HEAD REMOVAL 2. Place gasket in position over dowel pins. 3. Carefully guide cylinder head into place over dowel pins 1. Drain engine cooling system. and gasket. 2. Remove exhaust manifolds as outlined. 4. Coat threads of cylinder head bolts with Perfect Seal and 3. Remove intake manifold as described. install bolts finger-tight. 4. Remove valve mechanism as outlined. 5. Tighten each cylinder head bolt a little at a time in sequence shown in torque sequence chart until specified torque is reached. (Figure 1 or 1A) NOTE: For left side cylinder head, remove alternator and 6. Install exhaust manifolds as outlined. oil filter mounting brackets. 7. Install intake manifold as described. 8. Install and adjust valve mechanism as outlined. 5. Remove spark plugs. 9. Install valve covers. 6. Remove spark plug wire retainers from cylinder head. 10. Install spark plugs. Torque spark plugs to specifications. 7. Remove cylinder head bolts, cylinder head and gasket. 11. Install spark plug wire retainers. Place cylinder head on 2 blocks of wood to prevent damage. NOTE: For left side cylinder head installation, install alternator and oil filter mounting brackets. CLEANING and INSPECTION 12. Run engine, adjust timing and check for leaks. For cleaning and inspection, refer to "Cylinder Head and Valve Conditioning" (see "Index"). INSTALLATION CAUTION: Gasket surfaces on both head and block must be clean of any foreign matter and free of nicks or deep scratches. Figure 1. Cylinder Head Torque Sequence - 305/350 CID Models Cylinder bolt threads in block and threads on cylinder head bolts must be clean. (Dirt will affect bolt torque.) 1. On engines using a STEEL gasket, coat both sides of new gasket with Perfect Seal (C-92-34227). Spread sealer thin and even. A paint roller makes a good applicator. Too much sealer may hold gasket away from head or block. CAUTION: Use no sealer on engines which have a composition STEEL ASBESTOS gasket CYLINDER HEAD and VALVE CONDITIONING DISASSEMBLY 1. With cylinder head removed, remove valve rocker arm nuts, balls and rocker arms (if not previously done). 2. Compress valve springs with J-8062 tool (Figure 2) and remove valve retainers. Release compressor tool and remove spring caps, and springs and spring damper, then remove oil seals and valve spring spacer. 3. Remove valves from cylinder head and place valves in a rack in their proper sequence for reassembly in their original positions. CLEANING 1. Clean all carbon from combustion chambers and valve ports with J -8089 tool. (Figure 3) 2. Thoroughly clean valve guides with J-8101 tool. (Figure 4) 3. Clean all carbon and sludge from push rods, rocker arms and push rod guides. 4. Clean carbon from valves on a buffing wheel. 5. Clean carbon deposits and gasket material from cylinder head mating surfaces. Figure 2. Compressing Valve Spring Figure 1 A. Cylinder Head Torque Sequence - 454 CID Models 5C-8 - MERCRUISER ENGINE 977 R1 Figure 3. Cleaning Combustion Chambers INSPECTION 1. Inspect cylinder head for cracks in exhaust ports, combustion chambers and for external cracks to water chamber. 2. Inspect valves for bumed heads, cracked faces or damaged stems. NOTE: Excessive valve stem to bore clearance will cause excessive oil consumption and possible valve breakage. Insufficient clearance will result in noisy and sticky functioning of valve and disturb engine smoothness. 3. Measure valve stem clearance (Figure 5) as follows: Clamp a dial indicator on one side of cylinder head rocker arm Figure 4. Cleaning Valve Guides Figure 5. Measuring Valve Stem Clearance 977R1 cover gasket rail, locating indicator so that movement of valve stem from side-to-side (crosswise to the head) will cause a direct movement of indicator stem. Indicator stem must contact side of valve stem just above valve guide. With valve head dropped about 1/16" (1.6mm) off valve seat, move valve stem from side-to-side, using light pressure to obtain a clearance reading. If clearance exceeds specifications, it will be necessary to ream valve guides for oversize valves, as outlined under "Valve Guide Bores" (see "Index"). 4. Check valve spring tension with J-8056 spring tester. (Figure 6) NOTE: Springs should be compressed to specified height and checked against specification chart. Springs should be replaced if not within 10 lbs. of specified load (without dampers). 5. Inspect rocker arm studs for wear or damage. Inspect push rod guides for wear or damage. Figure 6. Checking Valve Spring Tension ROCKER ARM STUDS and PUSH ROD GUIDES REPAIRS 305/350 CID Models 1. Rocker arm studs, which are replaced because of wear or looseness, should be replaced with oversize studs. 2. Use Tool J-5802-1 to remove old stud by placing tool, flat washer and nut over stud, then turning nut. 3. Ream stud hole, whenever installing an oversize stud, using appropriate reaming tool. 4. Install new stud with Tool J-6880 or similar stud installing tool made for press-in type studs. Follow instructions with tool. 454 CID Models NOTE: Coat threads on cylinder head end of rocker arm studs with sealer before assembling to cylinder head. Push rod guides are attached to cylinder head by rocker arm studs. (Figure 7) Replace if worn and torque rocker arm studs to specifications. MERCRUISER ENGINE - 5C-9 Figure 7. Rocker Arm Stud and Push Rod Guide - 454 CID Models VALVE GUIDE BORE REPAIR Valves with oversize stems are available (see specifications). To ream valve guide bores for .015" (.381mm) oversize valves, use J-7910-5 tool. (Figure 8) Figure 8. Reaming Valve Guide VALVE SEAT REPAIR Valve seat reconditioning is very important, since seating of valves must be perfect for engine to deliver maximum power and performance. Another important factor is valve head cooling. Good contact between each valve and its seat in head is important to insure that heat in valve head will be properly dispersed. Several different types of equipment are available for reseating valve seats. Equipment manufacturer's recommendations should be followed carefully to attain proper results. Regardless of type of equipment, however, it is essential that valve guide bores be free from carbon or dirt to insure proper centering of pilot in valve guide. 5C-10 - MERCRUISER ENGINE 1. Install expanding pilot in valve guide bore and expand pilot. 2. Place roughing stone or forming stone over pilot and clean up valve seat only. Use a stone that is cut to specifications. 3. Remove roughing stone or forming stone from pilot, place finishing stone (cut to specifications) over pilot and cut just enough metal from seat to provide a smooth finish. Refer to "Specifications" Section 8 and Figure 10. 4. Narrow down valve seats to specified width by grinding with a 30° stone to lower seat and a 60° stone to raise seat. 5. Remove expanding pilot and clean cylinder head carefully to remove all chips and grindings from above operations. 6. Measure valve seat "out-of-round". (Figure 9) NOTE: Valve seats should be perfectly round to within .002" (.051 mm) total indicator reading. Figure 9. Measuring Valve Seat Concentricity VALVE REPAIR Pitted valves can be refaced to proper angle on a valve grinder, thus insuring correct relation between cylinder head seat and valve mating surface. Replace valves with excessive wear on stems or valves which are warped excessively. When an excessively-warped valve head is refaced, a knife edge will be ground on part or all of the valve head, due to amount of metal that must be removed to completely reface. Knife edges lead to breakage, burning or pre-ignition caused by heat localizing in this knife edge. If edge of valve head is less than 1/32" (.8mm) thick after grinding, replace the valve. (Figure 11) Various equipment is available for refacing valves. Manufacturer's recommendations should be carefully followed to attain proper results. 1. If necessary, dress the valve refacing machine grinding wheel to make sure it is smooth and true. Set chuck at angle specified for valve. Refer to "Specifications" and Figure 10. 2. Continue grinding until valve face is true and smooth all around the valve. If this makes valve head thin (1/32" [.8mm] minimum), valve must be replaced, or valve will overheat and burn. (Figure 11) 977 R1 Figure 10. Relation of Valve and Seat Angles 3. Remove valve from chuck and place stem in "V" block. Feed valve squarely against grinding wheel to grind any pit from rocker arm end of stem. NOTE: Only extreme end of valve stem is hardened to resist wear. Do not grind end of stem excessively. 4. After cleaning valve face and cylinder head valve seat of grinding particles, make pencil marks about (6.4mm) across the valve face, place valve in cylinder head and give valve /2-turn in each direction while exerting firm pressure on head of valve. 5. Remove valve and check face carefully. If all pencil marks have not been removed at point of contact with valve seat, repeat refacing operation and again recheck for proper seating. 06103 Figure 11. Critical Valve Dimensions REASSEMBLY 1. Insert valve in proper port. 2. Install valve spring spacer on valve spring seat, then install a new valve stem oil seal over valve and valve guide. 3. Set valve spring (with damper) and valve cap in place. (Figure 12) 4. Compress spring with tool J-8062. 5. Install valve locks and release compressor tool, making sure that locks seat properly in groove of valve stem. NOTE: Grease may be used to hold locks in place while releasing compressor tool. Figure 12. Valve Spring Installation 6. Install remaining valves. 7. Check installed height of the valve springs with a narrow, thin scale. A cutaway scale will help. (Figure 13) Measure from top of spacer (spring seat) to top of valve spring. (Figure 14) If this exceeds specified height, install a valve spring seat shim approximately 1/16" (1.6mm) thick. At no time should spring be shimmed to give an installed height under minimum specified. Figure 13. Cutaway Scale Figure 14. Measuring Valve Spring Installed Height MERCRUISER ENGINE - 5C-11 SEE SPECIFICATIONS OIL PAN REMOVAL 4. Remove oil dipstick and tube. 5. Remove oil pan and discard gaskets. 1. Remove engine from boat. 2. Drain crankcase oil. INSTALLATION 3. Drain water. 1. Thoroughly clean all gasket surfaces on oil pan, cylinder Coot Borh Surfaces block, crankcase front cover and rear main bearing cap. 2. Install new oil pan side gaskets on cylinder block, using Perfect Seal (C-92-34227) as a retainer. Install new oil pan rear gasket in rear main bearing cap groove with ends butting side gaskets. Install new oil pan front gasket in groove in crankcase front cover with ends butting side gaskets. (Figure 1) 3. Install oil pan and torque bolts to specifications. NOTE: Before installing the aluminum oil pan on engines, coat surfaces of front and rear oil pan seals (Figure 1) with Sealant (C-92-52238). 4. Install oil dipstick tube and dipstick. 04197 5. Install engine in boat. Fill engine with oil, start engine and Figure 1. Typical Oil Pan Gasket and Seal Locations check for leaks. OIL PUMP 1 - Shaft Extension 2 - Shaft Coupling 3 - Pump Body 4 - Drive Gear and Shaft 10-Washer 5 - Idler Gear 11 - Retaining Pin 6- Pickup Screen and Pipe 12 - Screws The oil pump consists of 2 gears and a pressure regulator valve enclosed in a 2-piece housing. Oil pump is driven by distributor shaft which is driven by a helical gear on camshaft. A baffle is incorporated on pickup screen to eliminate pressure loss and engine oil pump tubes are bent at special angles. REMOVAL 1. Remove oil pan as outlined. 2. Remove pump to rear main bearing cap bolt and remove pump and extension shaft. DISASSEMBLY (Figure 2) 1. Remove pump cover attaching screws and pump cover. 5C-12 - MERCRUISER ENGINE Figure 2. Oil Pump Assembly 7 - Pump Cover 8 - Pressure Regulator Valve 9 - Pressure Regulator Spring NOTE: Mark gear teeth for reassembly with same teeth indexing. 2. Remove idler gear, drive gear and shaft from pump body. 3. Remove pressure regulator valve retaining pin, pressure regulator valve and related parts. CAUTION: DO NOT remove pickup screen and pipe assembly, unless replacement is necessary. Loss of press-fit condition could result in an air leak and loss of oil pressure. 4. If pickup screen and pipe assembly need replacing, mount pump in a soft-jawed vise and extract pipe from pump. CAUTION: Do not disturb pickup screen on pipe. This is serviced as an assembly. CLEANING and INSPECTION 1. Wash all parts in cleaning solvent and dry with compressed 2. Inspect pump body and cover for cracks or excessive wear. 3. Inspect pump gears for damage or excessive wear. 4. Check for loose drive gear shaft in pump body. 5. Inspect inside of pump cover for wear that would permit oil to leak past ends of gears. 6. Inspect pickup screen and pipe assembly for damage to screen or pipe. 7. Check pressure regulator valve for fit. NOTE: Pump gears and body are not serviced separately. If pump gears or body are damaged or worn, replacement of entire oil pump assembly is necessary. 977 R1 REASSEMBLY CAUTION: Be careful of twisting, shearing or collapsing pipe while installing in pump. Pickup screen must be parallel to bottom of oil pan when oil pump is installed. 1. If pickup screen and pipe assembly was removed, it should be replaced with a new part. Loss of press-fit condition could result in an air leak and loss of oil pressure. Mount pump in a soft-jawed vise, apply sealer to end of pipe and, using tool J-8369, tap pipe in place with a plastic hammer. (Figure 3) NOTE: Oil internal parts liberally before installation. Figure 3. Installing Screen 2. Install pressure regulator valve and related parts. 3. Install drive gear and shaft in pump body. 4. Install idler gear in pump body with smooth side of gear toward pump cover opening. Align marks made in disassembly. Figure 4. Oil Pump Removal and Installation 5. Install pump cover and torque attaching screws to specifications. 6. Turn drive shaft by hand to check for smooth operation. INSTALLATION 1. Assemble pump and extension shaft to rear main bearing cap, aligning slot on top end of extension shaft with drive tang on lower end of distributor drive shaft. 2. Install pump to rear main bearing cap and torque to specifications. (Figure 4) NOTE: Oil pump screen is installed with bottom edge parallel to oil pan rails. 3. Install oil pan as outlined. TORSIONAL DAMPER REMOVAL 1. Remove drive belts. 2. Remove drive pulley, then remove damper retaining bolt. 01683 Figure 5. Removing Torsional Damper 977R1 NOTE: Tool J-6978 contains holes forming 2 patterns, a 2-bolt and a 3-bolt pattern. Holes for the 2-bolt pattern must be elongated. 3. Install tool J-6978 on damper and, turning puller screw, remove damper. (Figure 5) INSTALLATION CAUTION: Inertia weight section of torsional damper is assembled to hub with rubber-type material. Installation procedures must be followed, or movement of inertia weight section on hub will destroy tuning of torsional damper. DO NOT drive damper on. 1. Coat front cover seal contact area (on damper) with engine oil. 2. Install damper on crankshaft as follows: a. Place damper in position over key on crankshaft. b. Pull torsional damper onto crankshaft. Use tool J-21058. (Figure 6) If not available, pull damper on with a thick flat washer, a full-threaded /2-20x5" bolt and a 54-20 nut. MERCRUISER ENGINE - 5C-13 c. 3.4. c. 3.4. CAUTION: Install installing tool bolt in crankshaft with sufficient thread engagement (minimum [12.7mm] ). Remove tool from crankshaft, then install dampei retaining bolt and torque to specifications. Install drive pulley. Install drive belts. Figure 6. Installing Torsional Damper CRANKCASE FRONT COVER REMOVAL 1. Remove oil pan as outlined. 2. Remove torsional damper as instructed. 3. Remove water pump. 4. Remove crankcase front cover attaching screw. Remove front cover and gasket. INSTALLATION 1. Make certain that cover and cylinder block mating surface are clean and flat. 2. Coat oil seal with engine oil and, using a new cover gasket coated with Perfect Seal (C-92-34227), install cover and gasket over dowel pins on cylinder block. 3. Install cover screws and torque to specifications. 4. Install water pump. 5. Install torsional damper as described. 6. Install oil pan as outlined. OIL SEAL REPLACEMENT (with COVER REMOVED) 1. With cover removed, pry old seal out of cover from the front with a large screwdriver. CAUTION: Support cover at seal area when installing seal. (Tool J-971 may be used as support.) 2. Install new seal so that open end of seal is toward inside of cover and drive it into position with tool J-22102. (Figure 7) NOTE: Some left handed engines have helical grooves in seal REPLACEMENT (without COVER REMOVED) 1. With torsional damper removed, pry seal out of cover from the front with a large screwdriver, being careful not to damage surface on crankshaft. Figure 8. Installing Oil Seal (Cover Installed) 5C-14 - MERCRUISER ENGINE 977 R1 2. Install new seal so that open end of seal is toward inside of cover and drive it into position with tool J-22102. (Figure 8) FLYWHEEL REMOVAL 1. Remove engine from boat. 2. Remove transmission, if so equipped. 3. Remove flywheel housing and drive plate. 4. Remove flywheel. INSPECTION 1. Inspect drive plate for wear. 2. Check flywheel ring gear for worn or missing teeth. INSTALLATION 1. Clean mating surfaces of flywheel and crankshaft. 2. Install flywheel on crankshaft and align dowel hole of crankshaft flange and flywheel. (Figure 12) 3. Install coupler or drive plate. 4. Check flywheel runout by mounting dial indicator on machined surface of flywheel. 5. Runout should not exceed .008" (.203mm). If excessive, remove flywheel and check for burrs or replace flywheel. 6. Replace bell housing. 7. Install transmission, if so equipped. 8. Install engine in boat. OIL SEAL (REAR MAIN) REPLACEMENT Rear main bearing oil seal can be replaced (both halves) without removing crankshaft. NOTE: Always replace upper and lower seal as a unit. Install with lip facing toward front of engine. 1. Remove oil pan and oil pump as outlined. 2. Remove rear main bearing cap. Figure 11. Installing Rear Main Seal- Cylinder Block Inverted 3. Remove oil seal from rear main bearing cap by prying from bottom with a small screwdriver. 4. Lubricate lip of new seal with engine oil. Keep oil off parting line surface, as this is treated with glue. Insert seal into cap carefully, without allowing sharp edge of ridge to cut raised bead in center of seal outer surface. 5. To remove upper half of seal, use a small hammer and tap a brass pin punch on one end of seal until it protrudes far enough to be removed with pliers. (Figure 10) Figure 10. Removing Oil Seal (Upper Half) 977R1 MERCRUISER ENGINE - 5C-15 Apply Apply NOTE: Always wipe crankshaft surface clean before installing a new seal. Sealant 6. Lubricate lip of new seal with engine oil. Keep oil off part- to Shaded ing line surface. Use a modified feeler gauge (Figure 11) to protect raised bead of seal from being cut by sharp edge of cylinder block seal locating ridge. Gently push seal into place by hand or with a hammer handle. NOTE: To fabricate a tool for seal installation as described here, use a .004" or .006" stock feeler gauge, and grind sides (Figure 11) until projecting portion fits into 'U' of seal without scraping sides. After grinding, smooth edges of tool to prevent scratching of seal. 7. Apply Perfect Seal (C-92-34227) to cylinder block in seal area. (Figure 12) 8. Install rear main bearing cap (with new seal) and torque to specifications. MAIN BEARINGS Main bearings are precision insert type and do not utilize shim for adjustment. If clearances are excessive, a new bearing (both upper and lower halves) will be required. Bearings are available in standard size and .001", .002", .010" and .020" (,025mm. .051mm, .254mm and .508mm) undersize. Selective fitting of both rod and main bearing inserts is necessary in production to obtain close tolerances. Consequently, one half of a standard insert may have one half of a .001" undersize insert which will decrease clearance .0005" (.013mm) from using a full standard bearing. When a production crankshaft cannot be precision fitted by this method, it then is ground .009" (.229mm) undersize on main journals only. A .009" undersize bearing and .010" undersize bearing may be used for precision fitting in the same manner as previously described. Any engine fitted with a .009" undersize crankshaft will be identified by the following markings: • ".009" will be stamped on crankshaft counterweight forward of center main journal. Figure 2. Gauging Plastic on Journal • A figure "9 " will be stamped on block at left front oil CHECKING CLEARANCE pan rail. To obtain best results, use Plastigage (or its equivalent), a INSPECTION wax-like plastic material which will compress evenly between bearing and journal surfaces without damaging either surface. In general (except No. 2 bearing), lower half of bearing shows With engine upside-down, crankshaft will rest on upper a greater wear and most distress from fatigue. After inspection, bearings, and total clearance can be measured between lower if lower half is suitable for use, it can be assumed that the bearing and journal. upper half also is satisfactory. If lower half is wom or damaged, both upper and lower halves should be replaced. NOTE: To assure proper seating of crankshaft, all bearing Never replace one half without replacing the other. Typical cap bolts should be at their specified torque. In addition, bearing failures are shown in Figure 1. surface of crankshaft journal and bearing should be wiped clean of oil before checking fit of bearings. Remove oil seal from rear main bearing cap prior to checking clearance. 1. With oil pan and oil pump removed (starting with rear main bearing), remove bearing cap and wipe oil from- journal and bearing cap. 2. Place a piece of gauging plastic full width of bearing (parallel to crankshaft) on journal. (Figure 2) CAUTION: Do not rotate crankshaft while gauging plastic is between bearing and journal. 3. Install bearing cap and torque retaining bolts evenly to specifications. 977 R1 Areas Only Figure 12. Sealing Bearing Cap and Block 9. Install oil pump and oil pan as outlined. 01707 06005 Figure 1. Typical Bearing Failure 5C-16 - MERCRUISER ENGINE 4. Remove bearing cap. Flattened gauging plastic will be found adhering to either bearing shell or journal. 5. Use graduated scale (correlated in thousandths of an inch) on edge of gauging plastic envelope. Without removing gauging plastic, measure its compressed width (at widest point) with graduations on gauging plastic envelope. (Figure 3) Figure 3. Measuring Gauging Plastic NOTE: Main bearing journals usually wear evenly and are not oul-of-round. However, if a bearing is being fitted to an out-of-round journal (.001" [,025mm] maximum), be sure to fit to maximum diameter of journal. If bearing is fitted to minimum diameter, and journal is out-of-round .001", interference between bearing and journal wdl result in rapid bearing failure. If flattened gauging plastic tapers toward middle or ends, there is a difference in clearance indicating taper, low spot or other irregularity of bearing or journal. Be sure to measure journal with a micrometer if flattened gauging plastic indicates more than .001 " difference. 6. If bearing clearance is within specifications, bearing insert is satisfactory. If clearance is not within specifications, replace the insert. Always replace both upper and lower insert as a unit. NOTE: If a new bearing cap is being installed and clearance is less than .001", inspect for burrs or nicks. 7. A standard .001" or .002" (.025mm or .051mm) undersize bearing may produce proper clearance. If not. regrind crankshaft journal for use with next undersize bearing. 8. Proceed to next bearing. After all bearings have been checked, rotate crankshaft to see that excessive drag does not exist. 9. Measure crankshaft end play (see specifications) by forcing crankshaft to extreme front position. Measure at front end of rear main bearing with a feeler gauge. (Figure 4) 10. Install a new rear main bearing oil seal in cylinder block and main bearing cap. REPLACEMENT NOTE: Main bearings may be replaced with or without removing crankshaft. WITH CRANKSHAFT REMOVED 1. Remove and inspect crankshaft. 2. Remove main bearings from cylinder block and main bearing caps. 3. Coat bearing surfaces of new, correct size, main bearings with oil and install in cylinder block and main bearing caps. 4. Install crankshaft. WITHOUT CRANKSHAFT REMOVED 1. With oil pan, oil pump and spark plugs removed, remove cap on main bearing requiring replacement and remove bearing from cap. 2. Replace main bearing upper half as follows: a. Install main bearing removing and installing tool in crankshaft journal oil hole. NOTE: If tool is not available, bend a cotter pin. b. Rotate crankshaft clockwise (as viewed from front of engine). This will rojl upper bearing out of block. c. Oil new selected size upper bearing and insert plain (unnotched) end between crankshaft and notched side of block. Rotate bearing into place and remove tool from oil hole in crankshaft journal. 3. Oil new lower bearing and install in bearing cap. 4. Install main bearing cap with arrows pointing toward front of engine. 5. Torque main bearing cap bolts to specifications. Figure 4. Measuring Crankshaft End Play 977R1 MERCRUISER ENGINE - 5C-17 CONNECTING ROD BEARINGS Connecting rod bearings are precision insert type and do not utilize shims for adjustment. DO NOT FILE RODS OR ROD CAPS. If clearances are found to be excessive, a new bearing will be required. Bearings are available in standard size and .001" and .002" undersize for new and used standard size crankshafts and in .010" and .020" - undersize for reconditioned crankshafts. (.001 "=.025mm) INSPECTION and REPLACEMENT 1. With oil pan and oil pump removed, remove connecting rod cap and bearing. 2. Inspect bearing for wear or damage and replace unsatisfactory bearings. Typical bearing failures are shown in Figure 1. ' 3. Wipe bearings and crankpin clean of oil. 4. Measure crankpin for out-of-round or taper with a micrometer. If not within specifications, replace or recondition crankshaft. If within specifications, and a new bearing is to be installed, measure maximum diameter of crankpin to determine new bearing size required. 5. Measure new or used bearing clearances with Plastigage or its equivalent. NOTE: If a bearing is being fitted to an out-of-round crankpin, be sure to fit to maximum diameter of crankpin. If bearing is fitted to minimum diameter, and crankpin is out-of-round .001" (,025mm) or more, interference between bearing and crankpin will result in rapid bearing failure. Figure 5. Gauging Plastic on Crankpin a. Install bearing in connecting rod and cap. b. Place a piece of gauging plastic the full width of crankpin (parallel to crankshaft). (Figure 5) c. Install bearing cap and torque nuts evenly to specifications. Figure 6. Measuring Gauging Plastic CAUTION: Do not turn crankshaft with gauging plastic installed. d. Remove bearing cap and, using scale on gauging plastic envelope, measure gauging plastic width at the widest point. (Figure 6) 6. If clearance exceeds specifications, select a new. correct size bearing and recheck clearance. 7. Coat bearing surface with oil, install rod cap and torque nuts to specifications. 8. When all connecting rod bearings have been installed, tap each rod lightly (parallel to crankpin) to make sure they have clearance. 9. Measure all connecting rod side clearances (see specifications) between connecting rod caps. (Figure 7) 977 R1 5C-18 - MERCRUISER ENGINE CONNECTING ROD and PISTON ASSEMBLY REMOVAL 1. With oil pan, oil pump and cylinder head removed, use a ridge reamer to remove any ridge and/or deposits from upper end of cylinder bore. NOTE: Before ridge and/or deposits are removed, turn crankshaft until piston is at bottom of stroke and place a cloth on top of piston to collect cuttings. After ridge and/or deposits are removed, turn crankshaft until piston is at top of stroke, then remove cloth and cuttings. 2. Mark connecting rod and bearing caps left bank 1, 3, 5 and 7: right bank 2. 4, 6 and 8 from front to rear on same side as piston thrust. 3. Remove connecting rod cap and install tool J-5239 (3/8") or J-6305 (11/32'^ on studs. (Figure 8) Push connecting rod and piston assembly out of top of cylinder block. NOTE: It will be necessary to turn crankshaft slightly to disconnect and remove some connecting rod and piston assemblies. DISASSEMBLY MethodT PISTON SUPPORT TOOL If bosses on pistons do not allow piston support tool J-9510-1 to seat squarely on piston for press operations, tool modifications are necessary. To allow adequate clearance for these bosses, turn or grind upper portion of tool to dimensions shown in Figure 9. Tool modification, as described, does not affect tool application on other pistons. 01695 Figure 8. Removing Piston Assemblies 977R1 3/8" = 9.5mm 1/8" = 3.2mm Figure 9. Piston Support Tool Modification 1. Remove connecting rod bearings from connecting rods and caps. NOTE: If connecting rod bearings are being reused, place them in a rack to aid in reinstalling in their original rod and cap. 2. Remove piston rings with ring expander. 3. Place connecting rod and piston assembly in arbor press with piston on support. Press piston pin out of connecting rod and piston with piston pin tool J-6994. (Figure 10) 4. Remove assembly from arbor press and remove tools, piston pin, connecting rod and piston. MethodT 1. Use Tool Kit (J-24086-100), shown in Figure 11. Figure 10. Removing Piston 2. Position connecting rod onto tool rod support with rod support inserted between connecting rod end and piston. Align piston pin with hole located in top of arched base. (Figure 12) 3. Insert pin remover thru hole (located in top of arched base) and into piston pin hole. Press on pin remover to remove piston pin. (Figure 12) MERCRUISER ENGINE - 5C-19 10071 a - Arched Base c - Adjustable Installer b - Rod Support d - Piston Pin Guide e - Piston Pin Remover Figure 11. Tool (J-24086-100) Parts Identification CLEANING and INSPECTION CONNECTING RODS 1. Wash connecting rods in cleaning solvent and dry with compressed air. 2. Check for twisted or bent rods and inspect for nicks or cracks. Replace damaged connecting rods. 10072 a - Piston Pin Remover c - Piston b - Arched Base d - Connecting Rod e - Rod Support Figure 12. Removing Piston Pin 5C-20 - MERCRUISER ENGINE PISTONS 1. Clean varnish from piston skirts and pins with a cleaning solvent. DO NOT WIRE BRUSH ANY PART OF PISTON. Clean ring grooves with a groove cleaner and make sure oil ring holes and slots are clean. 2. Inspect piston for cracked ring lands, skirts or pin bosses, waw worn ring lands, scuffed or damaged skirts or eroded areas at top of piston. Replace pistons which are damaged or show signs of excessive wear. 3. Inspect grooves for nicks or burrs that might cause rings to hang up. 4. Measure piston skirl (across centerline of piston pin) and check clearance as outlined under "Piston Selection". (Use "Index") PISTON PINS 1. Piston pin clearance is designed to maintain adequate clearance under all engine operating conditions. Because of this, piston and piston pin are a matched set and not serviced separately. 2. Inspect piston pin bores and piston pins for wear. Piston pin bores and piston pins must be free of varnish or scuffing when measured. Measure piston pin with a micrometer and piston pin bore with a dial bore gauge or inside micrometer. If clearance is in excess of the .001" (.025mm) wear limit, replace piston and piston pin assembly. PISTON RINGS All compression rings are marked on upper side of ring. When installing compression rings, make sure that marked side is toward top of piston. Oil control rings are a 3-piece type, consisting of 2 segments (rails) and a spacer. 0167" Figure 13. Checking Ring Gap 1. Select rings comparable in size to piston being used. 2. Slip compression ring in cylinder bore, then press ring down into cylinder bore about (6.35mm) (above ring travel). Be sure that ring is square with cylinder wall. 977 R1 3. Measure space or gap between ends of ring with a feeler 8. Install piston ring as shown in Figure 15. Use (J-22250) gauge. (Figure 13) piston ring expanders for compression ring installation, 4. If gap between ends of ring is below specifications, remove a. Install oil ring spacer in groove and insert anti-rotation ring and try another for fit. tang in oil hole. 5. Fit each compression ring to cylinder in which it is going b. Hold spacer ends butted and install lower steel oil ring to be used. rail with gap properly located. 6. Clean and inspect pistons, if not previously done. c. Install upper steel oil ring rail with gap properly 7. Slip outer surface of top and second compression ring into located. respective piston ring groove and roll ring entirely around d. Flex the oil ring assembly to make sure ring is free. If the groove (Figure 14) to make sure that ring is free. If binding occurs at any point, the cause should be binding occurs at any point, determine cause. If caused by determined and, if caused by ring groove, remove by ring groove, remove by dressing with a fine cut file. If dressing groove with a fine cut file. If binding is caused binding is caused by a distorted ring, check a new ring. by a distorted ring, check a new ring. e. Install lower compression ring, using ring expander, and check location of gap. f. Install top compression ring with gap properly located. 9. Proper clearance of piston ring in its piston ring groove is very important to provide proper ring action and reduce wear. Therefore, when fitting new rings, clearances between ring and groove surfaces should be measured. (Figure 16) See "Specifications" Section 8. Figure 16. Checking Groove Clearance REASSEMBLY Method 1 CAUTION: DO NOT oil piston pin or connecting rod before rod end is to be heated for installation. 1. Heat piston pin end of connecting rod. •Of 01700 Figure 14. Rolling Ring in Ring Groove Figure 15. Ring Gap Location 977R1 Figure 17. Connecting Rod and Oven MERCRUISER ENGINE - 5C-21 NOTE: An oven is recommended to heat piston pin end of connecting rod prior to piston installation. (Figure 17) 2. Place support tool J-6994 with spring and pilot in place on arbor press. 3. Position piston on connecting rod with notched side of piston (Figure 18) and connecting rod tangs aligned. 08670 Figure 18. Connecting Rod and Piston Assembly Reference - Support Figure 19. Piston Pin and Tool 5C-22 - MERCRUISER ENGINE 05046 4. Place piston on support, indexing pilot through piston and rod. 5. Place installer (Figure 19) on piston pin, start piston pin and press on installer until pilot bottoms in support. 6. Remove installer from connecting rod and piston assembly and check piston for freedom of movement on piston pin. 7. Allow connecting rod and piston assembly to cool, then oil piston pin. Method 2 1. Lubricate piston pin, piston pin hole in piston and hole in rod end with a light coat of engine oil. a - Jam Nut d - Piston b - Adjustable Installer e - Connecting Rod c - Arched Base t - Piston Pin g - Rod Support Figure 20. Installing Piston Pin 2. Position rod onto rod support and piston onto rod end. Insert piston pin guide thru bottom piston pin hole and into connecting rod. Place piston pin thru top side of piston. (Figure 20) 3. Adjust adjustable installer to setting specified on chart (which came with tool) for particular piston installation. Lock adjustable installer with jam nut. 4. Insert adjustable installer thru hole (located on top of arched base) and into piston pin hole. Carefully press on adjustable installer until installer bottoms-out on arched base to install piston pin. 977 R1 INSTALLATION NOTE: Cylinder bores must be clean before piston installation. Clean with a light honing, as necessary. Then clean with hot water and detergent wash. After cleaning, swab bores several times with light engine oil and a clean cloth, then wipe with a clean dry cloth. 1. Lubricate connecting rod bearings and install in rods and rod caps. 2. Lightly coal pistons, rings and cylinder walls with light engine oil. 3. With bearing caps removed, install tool J-6305 (11/32") on connecting rod bolts. Figure 22. Installing Connecting Rod and Piston Assemblies CAUTION: Be sure ring gaps are properly positioned as previously outlined. 4. Install each connecting rod and piston assembly in its respective bore. Install with connecting rod bearing tangs toward outside of cylinder block. (Figure 21) Use tool J-8307 to compress rings. (Figure 22) Guide connecting rod into place on crankshaft journal with tool J-6305 (11/32"). Lsea hammer handle with light blows to install piston into bore. Hold ring compressor firmly against cylinder block until all piston rings have entered cylinder bore. (Figure 22) NOTE: Be sure to install new pistons in same cylinders for which they were fitted, and used pistons in same cylinder from which they were removed. Each connecting rod and bearing cap should be marked, beginning at front of engine (1, 3. 5 and 7 in left bank and 2, 4. 6 and 8 in right bank). Numbers on connecting rod and bearing cap must be on same side when installed in cylinder bore. If a connecting rod is ever transposed from one block or cylinder to another, new bearings should be fitted and connecting rod should be numbered to correspond with new cylinder number. 5. Remove tool J-6305. 6. Install bearing caps and torque nuts to specification. NOTE: If bearing replacement is required, refer to "Connecting Rod Bearings". CRANKSHAFT REMOVAL Remove connecting rod bearing caps, then push piston and rod assemblies toward heads. 11. Remove main bearing caps and carefully lift crankshaft out 1. Remove engine from boat. of cylinder block. Remove rear main bearing oil seal from 2. Drain block and crankcase oil. Disconnect all hoses. cylinder block and rear main bearing cap. 3. Remove starter motor, flywheel housing and flywheel. 12. If new main and/or connecting rod bearings are to be Place engine in repair stand. installed, remove main bearing inserts from cylinder block 4. Remove belts, crankshaft pulley and water pump. and bearing caps, and/or connecting rod bearing inserts 5. Remove torsional damper and crankcase front end cover. from connecting rod and caps. Install new bearings 6. Remove spark plugs. following procedures outlined in this section. (See 7. Remove camshaft sprocket and timing chain. Remove "Index".) crankshaft oil slinger. 8. Remove crankshaft sprocket. CLEANING and INSPECTION 9. Remove oil pan and oil pump. 10. Make sure all bearing caps (main and connecting rods) are 1. Wash crankshaft in solvent and dry with compressed air. marked so they can be installed in their original locations. 2. Measure main bearing journals and crankpin dimensions 977R1 MERCRUISER ENGINE - 5C-23 with a micrometer for out-of-round, taper or undersize (see "Specifications" Section 8). 3. Check crankshaft for runout (by supporting at front and rear main bearings journals in "V " blocks) and check at front and rear intermediate journals with a dial indicator (see "Specifications" Section 8). 4. Replace or recondition crankshaft if not meeting specifications. INSTALLATION NOTE: Be sure that all bearings and crankshaft journals are clean. 1. Install a new rear main bearing oil seal in cylinder block and rear main bearing cap. 2. Carefully lower crankshaft into place. BE CAREFUL not to damage bearing surface. 3. Check clearance of each main bearing,following procedure outlined under "Main Bearing Clearance" in this section,see "Index". If bearing clearances are satisfactory, apply a light coat of engine oil to journals and bearings. 4. Install all bearing caps and bolts. Torque all main bearing cap bolts to specifications. When tightening rear main bearing cap, torque bolts 10 to 12 ft. lbs. (1.4 to 1.7mkg) first, then tap end of crankshaft to the rear with lead hammer (this will locate bearing cap and bearing). Then tap crankshaft forward (this will line up both upper and lower crankshaft bearing thrust surfaces). 5. Check crankshaft end play by forcing crankshaft to its extreme front position. Check at front end of rear main bearing with feeler gauge. (Figure 23) Clearance should be from .001" to .006" (.025mm to .152mm) with new bearing. If greater than maximum .009" (.229mm) clearance, rear main bearing must be replaced. Figure 23. Measuring Crankshaft End Play 6. Install oil pump and pan as outlined. 7. Install crankshaft sprocket, oil slinger, camshaft sprocket and timing chain. 8. Install crankcase front cover and torsional damper. 9. Remove engine from repair stand and install water pump, flywheel, flywheel housing and starter motor. 10. Install crankshaft pulley and belts. 11. Install spark plugs. 12. Install engine in boat, fill crankcase and install hoses. 5C-24 - MERCRUISER ENGINE 977 R1 TIMING CHAIN and/or SPROCKETS REMOVAL 1. Remove torsional damper and crankcase front cover as outlined. 2. Crank engine until marks on camshaft and crankshaft sprockets are in alignment. (Figure 1) 3. Remove camshaft sprocket to camshaft bolts. 4. Remove camshaft sprocket and timing chain together. Sprocket is a light press fit on camshaft. If sprocket does not come off easily, a light blow on lower edge of sprocket (with a plastic mallet) should dislodge the sprocket. 1. Install timing chain on camshaft sprocket. Hold sprocket vertical with chain hanging down and orient to align marks on camshaft and crankshaft sprockets. (Figure 2) NOTE: Do not attempt to drive sprocket on camshaft, as welsh plug at rear of engine can be dislodged. 2. Draw camshaft sprocket onto camshaft, using the 3 mounting bolts. Torque to specifications. 3. Lubricate timing chain with engine oil. Install crankcase front cover and torsional damper as outlined. CAMSHAFT MEASURING LOBE LIFT attach an auxiliary starter switch and "bump" engine over) until push rod is in fully raised position. NOTE: Procedure is similar to checking valve timing. If 5. Compare total lift, recorded from dial indicator, with improper valve operation is indicated, measure lift of each "Specifications" Section 8. push rod in consecutive order and record readings. 6. Continue to rotate engine until indicator reads zero. This will be a check on accuracy of original indicator reading. 1. Remove valve mechanism as outlined (see "Index"). 7. If camshaft readings for all lobes are within specifications, 2. Position indicator with ball socket adapter (tool J-8520) remove dial indicator assembly. on push rod. (Figure 3) Be sure that push rod is in lifter 8. Install and adjust valve mechanism as outlined. socket. 3. Rotate crankshaft damper slowly in direction of rotation REMOVAL until lifter is on heel of cam lobe. At this point, push rod will be in its lowest position. 1. Remove valve lifters as outlined. 4. Set dial indicator on zero, then rotate balancer slowly (or 2. Remove crankcase front cover as outlined. 977R1 MERCRUISER ENGINE - 5C-25 Figure 2. Installing Timing Chain INSTALLATION Figure 1. Timing Sprocket Marks Figure 3. Measuring Camshaft Lobe Lift 3. Remove fuel pump and fuel pump push rod. 4. Remove camshaft sprocket bolts, then remove camshaft sprocket and timing chain. NOTE: Sprocket is a light press fit on camshaft. To dislodge, tap lightly on lower edge of camshaft sprocket with a plastic hammer. 5. Install two 5/16-18 bolts in camshaft sprocket bolt holes and carefully remove camshaft. (Figure 4) Figure 4. Removing and Replacing Camshaft CRANKSHAFT REMOVAL 1. Remove torsional damper and crankcase front cover as outlined. 2. Remove camshaft timing chain as outlined. 3. Use tool J-1619 for crankshaft sprocket removal. INSPECTION Measure camshaft bearing journals with a micrometer for out-of-round condition. If journals exceed .001" (.025mm'1 out-of-round, camshaft should be replaced. Also check camshaft for alignment with "V" blocks and dial indicator (Figure 5) which indicates exact amount camshaft is out-of-true. If out more than .002" (.051mm) (dial indicator reading) camshaft should be replaced. On engines with timing gears, inspect camshaft gear and thrust plate for wear or damage. Measure camshaft end play which should be .001" to .005" (,025mm to .127mm). (Figure 5) Figure 5. Checking Camshaft Alignment INSTALLATION 1. Install two 5/16-18 bolts in camshaft bolt holes, then lubricate camshaft journals with engine oil and install camshaft, being careful not to damage bearings. (Figure 4) Remove the two 5/16-18 bolts. 2. Install timing chain on camshaft sprocket, then align marks on camshaft and crankshaft sprockets and connect chain to crankshaft sprocket. .Align dowel on camshaft with dowel hole in camshaft sprocket and install sprocket on camshaft. (Figure 2) CAUTION: Do not hammer crankshaft sprocket onto camshaft. This may loosen rear camshaft welsh plug. 3. Draw camshaft sprocket into camshaft, using the mounting bolts. Torque bolts to specifications. 4. Lubricate timing chain with engine oil. 5. Install fuel pump push rod and fuel pump. 6. Install crankcase front cover and valve lifters as outlined. SPROCKETS INSTALLATION 1. Use tool J-21058 for installation of crankshaft sprocket. 2. Install camshaft timing chain as outlined. 3. Install crankcase front cover and torsional damper as outlined. 977 R1 5C-26 - MERCRUISER ENGINE CAMSHAFT REMOVAL Camshaft bearings can be replaced while engine is disassembled for overhaul or without complete disassembly. To replace bearings without complete disassembly, remove camshaft and crankshaft, leaving cylinder heads attached and pistons in place. Before removing crankshaft, tape threads of connecting rod bolts to prevent damage to crankshaft. Fasten connecting rod against sides of engine so that they will not interfere while replacing camshaft bearings. 1. With camshaft and crankshaft removed, drive camshaft rear plug from cylinder block. NOTE: This procedure is based on removal of bearings center of engine first, thus requiring a minimum amount of turns to remove all bearings. 2. Using tool set J-6098-01 (with nut and thrust washer installed to end of threads), position pilot in front camshaft bearing and install puller screw through pilot. NOTE: Tool adaptor J-6098-8 is used with tool setJ-6098 for replacing cam bearings. Combination of above tools is tool set J-6098-01. 3. Install tool with shoulder toward bearing. Be sure a sufficient amount of threads are engaged. 4. Using 2 wrenches, hold puller screw while turning nut. (Figure 6) When bearing has been pulled from bore, remove tool and bearing from puller screw. 5. Remove remaining bearings (except front and rear) in same manner. It will be necessary to position pilot in rear camshaft bearing to remove rear intermediate bearing. 01690 Figure 6. Replacing Camshaft Bearings 6. Assemble remover tool on driver handle and remove front and rear camshaft bearings by driving toward center of cylinder block. (Figure 7) INSPECTION With camshaft removed, inspect bearings for wear or damage and replace if necessary. BEARINGS INSTALLATION Install front and rear camshaft bearings first. These bearings act as guides for pilot and center the remaining bearings being pulled into place. Nos. l-thru-4 cam bearing oil hole must be aligned with oil holes in cam bearing bore. No. 5 bearing bore is grooved, and cam bearing must be positioned at or near 6 o'clock position. 1. Assemble installer tool on driver handle and install front and rear camshaft bearings by driving toward center of cylinder block. (Figure 7) Figure 7. Replacing Rear Camshaft Bearing CAUTION: Oil holes in bearings must line up with oil holes in cylinder block. 2. Position pilot in front camshaft bearing and install puller screw through pilot. 3. Position camshaft bearing in bore, then install installer tool on puller screw with shoulder toward bearing. 4. Using 2 wrenches, hold puller screw while turning nut. After bearing has been pulled into bore, remove tool from puller screw and check alignment of oil hole in camshaft bearing. (Figure 6) 5. Install remaining bearings in same manner. It will be necessary to position pilot in rear camshaft bearing to install rear intermediate bearing. 6. Install a new camshaft rear plug. NOTE: Install plug flush to 1/32" (.8mm) deep and parallel with rear surface of cylinder block. 977R1 MERCRUISER ENGINE - 5C-27 CYLINDER BLOCK CLEANING and INSPECTION REPAIRS 1. Remove all engine components as previously outlined. 2. Wash cylinder block thoroughly in cleaning solvent and clean all gasket surfaces. 3. Remove oil gallery plugs and clean all oil passages. NOTE: These plugs may be removed with a sharp punch, or they may be drilled and pried out. 4. Clean and inspect water passages in cylinder block. 5. Inspect cylinder block for cracks in cylinder walls, water jacket valve lifter bores and main bearing webs. 6. Measure cylinder walls for taper, out-of-round or excessive ridge at top of ring travel. This should be done with a dial indicator or inside micrometer. (Figure 8 and 9) Carefully work gauge up and down cylinder to determine taper and turn it to different points around cylinder wall to determine out-of-round condition. If cylinders exceed specifications, boring and/or honing will be necessary. 01697 Figure 8. Measuring Cylinder Bore Center Line of Engine "A" = At right angle to center- line of engine "B" = Parallel to centerline of engine "Out-of-round" = Difference between "A" and "B" 'Taper" = Difference between measurement "A" at top of cylinder bore and "A" measurement at bottom of cylinder bore. . 05042 Figure 9. Cylinder Measurement CYLINDER CONDITIONING 1. Performance of the following operation depends upon engine condition at time of repair. 2. If cylinder block inspection indicates that block is suitable for continued use (except for out-of-round or tapered cylinders), they can be conditioned by honing or boring. 3. If cylinders have less than .005" (.127mm) taper or wear, they can be conditioned with a hone and fitted with high limit standard size piston. A cylinder bore of less than .005" wear or taper may not clean up entirely when fitted to a high limit piston. To entirely clean up the bore, it will be necessary to rebore for an oversize piston. If more than .005" taper or wear, bore and hone to smallest oversize that will permit complete resurfacing of all cylinders. 4. When pistons are being fitted and honing is not necessary, cylinder bores may be cleaned with a hot water and detergent wash. After cleaning, swab cylinder bores several times with light engine oil and a clean cloth, then wipe with a clean drv cloth. CYLINDER BORING 1. Before using any type boring bar. file off top of cylinder block to remove dirt or burrs. This is very important to prevent boring bar tilt, with result that rebored cylinder wall is not at right angles to crankshaft. 2. Measure piston to be fitted with a micrometer, measuring at center of piston skirt and at right angles to piston pin. Bore cylinder to same diameter as piston and hone to give specified clearance. NOTE: Hone cylinders as outlined under "Cylinder Honing" and ".Piston Selection ", following. 3. Carefully observe instructions furnished by manufacturer of equipment being used. CYLINDER HONING 1. Follow hone manufacturers recommendations for use of hone and cleaning and lubrication during honing. 2. Occasionally, during the honing operation, thoroughly clean cylinder bore and check piston for correct fit in cylinder. 3. When finish-honing a cylinder bore to fit a piston, move hone up-and-down at a sufficient speed to obtain very fine uniform surface finish marks in a cross-hatch pattern of approximately 30° to cylinder bore. Finish marks should be clean but not sharp, free from imbedded particles and torn or folded metal. 4. Permanently mark piston (for cylinder to which it has been fitted) and proceed to hone cylinders and fit remaining pistons. CAUTION: Handle pistons with care and do not attempt to force them through cylinder until cylinder is honed to correct size, as this type piston can be distorted by careless handling. 5C-28 - MERCRUISER ENGINE 977 R1 5. Thoroughly clean cylinder bores with hot water and detergent. Scrub well with a stiff bristle brush and rinse thoroughly with hot water. It is extremely essential that a good cleaning operation be performed. If any abrasive material remains in cylinder bores, it will rapidly wear new rings and cylinder bores in addition to bearings lubricated by the contaminated oil. Swab bores several times with light engine oil on a clean cloth, then wipe with a clean dry cloth. Cylinder should not be cleaned with kerosene or gasoline. Clean remainder of cylinder block to remove excess material spread during honing operation. PISTON SELECTION 1. Check USED piston to cylinder bore clearance as follows: a. Measure "cylinder bore diameter" with a telescope gauge (2Vi" [63.5mm] from top of cylinder bore). b. Measure "piston diameter" (at skirt across center line of piston pin). c. Subtract piston diameter from cylinder bore diameter to determine "piston-to-bore clearance". d. Determine if "piston-to-bore clearance" is in acceptable range shown in "Specifications" Section 8. 2. If used piston is not satisfactory, determine if a new piston can be selected to fit cylinder bore within acceptable range. 3. If cylinder bore must be reconditioned, measure new piston diameter (across centerline of piston pin), then hone cylinder bore to correct clearance (preferable range). 4. Mark piston to identify cylinder for which it was fitted. 977R1 MERCRUISER ENGINE - 5C-29 SECTION 5 - ENGINE INDEX Page General 5D-1 Tools 5D-1 Removal/Disassembly/Cleaning-lnspection/Reassembly/ lnstallation 5D-2 Exhaust TubeWaterShutter 5D-2 Exhaust Manifold 5D-2 Intake Manifold 5D-3 Rocker Arm Cover 5D-5 Valve Clearance 5D-5 Valve Mechanism 5D-5 Hydraulic Valve Lifters 5D-6 Valve Spring, Retainer or Stem Seal Replacement (with Cylinder Head Installed) 5D-7 Cylinder Head and Valves 5D-8 Alternator Rotor 5D-12 Stator 5D-12 Front Cover and/or Water Pump Shaft and Front Cover Oil Seals 5D-13 Timing Chain and Sprockets 5D-14 Timing Chain Deflection 5D-14 Engine Coupler and/or Flywheel 5D-15 Oil Pan 5D-15 Oil Pump 5D-15 OilSeal (RearMain) 5D-17 Camshaft 5D-18 Camshaft Gear Replacement 5D-19 Camshaft Bearings 5D-19 Crankshaft 5D-19 Main Bearings 5D-22 Connecting Rod Bearings 5D-23 Piston and Rod Assembly 5D-25 Cylinder Block 5D-29 GENERAL Some repairs, that are listed in this section, must be completed All specifications are listed in Section 8. Lubricate all moving with engine removed from boat. Engine removal depends upon parts (during reassembly) with engine oil. Apply Perfect Seal type of repair and boat design. Place engine on repair stand for on threads of and under head of cylinder head bolts and on major repairs. threads of all cylinder block external bolts, screws and studs. TOOLS All "J"- prefix (special) tools* in this Section may be purchased .All "T " prefix (special) tools* herein may be purchased from: from: Kent-Moore, Inc. Owatonna Tools, Inc. 28635 Mound Road Attn: Ford Order Desk Warren, Ml 48089 Owatonna, MN 55060 *If ordering tool number(s), shown in discussion on following pages, number(s) may be superseded by newer tool(s) which will be sent by tool manufacturer listed above. 977R1 MERCRUISER ENGINE - 5C-1 REMOVAL/DISASSEMBLY/CLEANING - INSPECTION REASSEMBLY/INSTALLATION EXHAUST TUBE WATER SHUTTER The engine is equipped with exhaust shutter in exhaust tube. Loose fit between shutter shaft and support brackets may- make a rattling noise at idle speed. This noise can be corrected as follows: 1. Drain water from exhaust manifold and elbow. 2. Loosen hose clamps which fasten exhaust bellows to exhaust tube. 3. Remove exhaust elbow fastener nuts and remove elbow and bellows as an assembly. Scrape gasket material from manifold and elbow. 4. Thoroughly clean area between shutter support brackets and exhaust tube with cleaning solvent and small brush. 5. Fill entire area between support brackets and tube with Silicone Seal. (Figure 1) Allow sealant to cure for 24 7 hours. 6. Reinstall elbow (using new gasket) and connect bellows. Torque hose clamps to 35 to 38 in. lbs. (40 to 44kg-cm). EXHAUST MANIFOLD a - Exhaust Tube b - Shutter c - Shutter Support Brackets Figure 1. Sealant Application REMOVAL (Figure 2) REASSEMBLY (Figure 2) 1. Drain engine coolant systems. 1. Install new gasket and end cap on aft end of manifol 2. Disconnect wire from temperature sending unit (located body (with hose connector facing toward engine side of on thermostat/distribution housing). manifold). 3. Disconnect all hoses and exhaust bellows from manifold 2. Place new gasket, plate, second gasket and exhaust elbow assembly. onto manifold body, as shown in Figure 2. Install 4. Drain engine oil and remove oil dipstick tube. lockwasher and nuts. Torque nuts to specifications. 5. Support manifold and remove exhaust manifold fasteners. 3. Apply Perfect Seal to threads and install temperature Remove manifold assembly and discard gasket. sender and brass plug. 4. Install new gasket, thermostat/distribution housing and DISASSEMBLY (Figure 2) attaching bolts, using copper washers. 5. Place thermostat into its cavity in housing. Install new1. Remove closed cooling reservoir from thermostat/ gasket, closed cooling reservoir and attaching bolts with distribution housing and remove thermostat. flat washers and lockwashers. 2. Remove thermostat/distribution housing from manifold body. 3. Remove temperature sender and brass plug from INSTALLATION thermostat/distribution housing. 1. Using a new gasket, position manifold assembly onto 4. Remove exhaust elbow from manifold body. cylinder head and install lockwashers, nuts and bolts. 5. Remove end cap from aft end of manifold body. Torque fasteners to specifications. 2. Install dipstick tube to oil pan and to support clamp CLEANING and INSPECTION located on exhaust manifold fastener bolt. 1. Clean gasket material from all surfaces and wash parts in 3. Connect all hoses and exhaust bellows to manifold solvent. assembly. Tighten hose clamps securely. 2. Inspect all parts carefully. Machined surfaces must be clean 4. Connect engine harness wire to temperature sender (loand free of all marks and deep scratches, or water and/or cated on thermostat/distribution housing). exhaust leaks may result. 5. Fill engine to proper oil level and closed cooling system to 3. Check water passages for sand, silt or other foreign proper fluid level. material. Passages must be clean for efficient cooling. 6. Pressure check the cooling system, using automotive 4. If more thorough inspection is desired, pipe plugs may be radiator cap tester. Follow tool manufacturer's instruc removed from exhaust manifold and exhaust elbow. tions. 977 R1 5C-2 - MERCRUISER ENGINE 09812 a - Thermostat/Distribution Housing Bolts (4) r - Lockwashers (4) b - Copper Washers (4) s - Reservoir to Thermostat/Distrib. Housing Long c - Thermostat-Distribution Housing t - Reservoir Cap d - Brass Plug u - Reservoir Cap Gasket e - Temperature Sender V - Overflow Fitting f - Thermostat/Distribution Housing to Manifold Body Gasket w - Bleed Hose Fitting g - Manifold Body X - Lockwashers (8) h - Manifold Body to Cylinder Head Gasket y - Manifold Body to Cylinder Head Bolts (6) i - Drain Plug z - Manifold Body to Cylinder Head Nuts (2) j - End Cap to Manifold Body Gasket aa - Exhaust Elbow k - End Cap bb - Lockwashers (4) 1 - End Cap to Manifold Body Bolts (4) cc - Exhaust Elbow to Manifold Body Nuts (4) m - Thermostat dd - Hose Connector Elbow n - Reservoir to Thermostat/Distribution Housing Gasket ee - Manifold Body to Plate Gasket 0 - Closed Cooling Reservoir ff - Plate P - Flat Washers (4) gg - Plate to Exhaust Elbow Gasket q - Reservoir to Thermostat/Distribution Housing Short Bolts hh - Bleed Hose Fitting (2) ii - Drain Plug Figure 2. Exhaust Manifold Assembly INTAKE MANIFOLD REMOVAL 2. Support intake manifold and remove 7 manifold fasteners and engine harness retaining clamps. Remove manifold 1. Disconnect the following: assembly and discard gasket. a. Wires from choke cover. 3. Carburetor may be removed from intake manifold, if b. Throttle cable. necessary. c. Carburetor linkage from manifold. d. Fuel pump vent tube from carburetor. CLEANING and INSPECTION e. Crankcase breather hose from flame arrestor. f. Fuel line from carburetor. 1. Remove all gasket material from machined surfaces of g. Water hoses from manifold. manifold. 977R1 MERCRUISER ENGINE - 5C-3 2. Clean manifold in a suitable solvent and dry with compressed air. 3. Inspect manifold for cracks, damaged gasket surfaces or other defects. 4. Replace studs which are stripped or damaged. 5. Repair drain plug and stud hole threads, if damaged or corroded. 6. After repairs are made, remove all filings and foreign matter that may have entered manifold. INSTALLATION 1. Apply Perfect Seal on both surfaces of intake manifold to cylinder head gasket. Position new gasket and intake manifold to cylinder head. Install fastener bolts with flat washers and engine harness retaining clamps. (Figure 3) 2. Use new gasket and install carburetor, if removed. 3. Connect the following: a. Water hoses to manifold. b. Fuel line to carburetor. Place Perfect Seal on thread1" and torque to specifications. Hold banjo fitting wit wrench to prevent twisting fuel line while torquing. c. Crankcase breather hose to flame arrestor. d. Fuel pump vent tube to carburetor. e. Carburetor linkage to manifold. Lubricate swivel points with Multipurpose Lubricant. f. Throttle cable. g. Connect wire to choke cover. 4. Pressure check the cooling system, using automotive radiator cap tester. Follow tool manufacturer's instructions. a - Manifold Assembly i - Washer t - Manifold Fastening Bolts (7) b - Manifold to Cylinder Head Gasket k - Link Rod u - Plug c - Carburetor to Manifold Gasket I - Link Rod to Throttle Lever Swivel v - Engine Harness Retaining Clamps (2) d - Carburetor Mounting Nuts (4) m - Throttle Lever w - Throttle Cable Attaching Stud e - Washers (4) n - Large Washer X - Washers (2) 09811 f - Link Rod to Carburetor Swivel Nut 0 - Small Washer y - Nut 9 P - Small Washer - Link Rod to Throttle Lever Swivel Nut z - Set Nut h - Large Washer q - Washer aa - Throttle Stop Screw i - Link Rod to Carburetor Swivel r - Throttle Lever Fastening Bolt bb - Carburetor Assembly s - Washers (9) Figure 3. Intake Manifold Assembly 5C-4 - MERCRUISER ENGINE 977 R1 ROCKER ARM COVER REMOVAL 2. Clean gasket surface on cover and cylinder head, using a scraper, then a degreaser. 1. Remove spark plug high tension leads from their retainer. 3. Gasket surface must be free of deep scratches, or oil leaks 2. Disconnect crankcase ventilation hose from rocker arm may result. cover. 3. Remove attaching bolts. INSTALLATION 4. Remove rocker arm cover and gasket. 1. Use a new gasket and install rocker arm cover and torque to specifications. CLEANING and INSPECTION 2. Connect crankcase ventilation hose to rocker arm cover. 1. Wash cover in solvent and dry with compressed air. 3. Place spark plug high tension leads into their retainer. VALVE CLEARANCE Valve clearance must be checked whenever valve face and/or seat is ground, valve stem ground, cylinder head and/or block mating surface is milled, or if a noise is present in valve train (which is not caused by collapsed hydraulic lifter). Use following procedure to check valve clearance (valves are not adjustable): 1. Remove rocker arm cover as outlined, preceding. 2. With valve closed (piston at TDC) and lifter fully collapsed (using special tool Part No. T711P-6513A), check clearance between rocker arm and valve stem. (Figure 4) 3. If clearance is not within specifications, check for worn parts in valve train. If parts are not worn, install push rod of correct length (see Parts Manual) to bring valve clearance within specifications. (See Section 8 for specifications.) a - Tool b- Feeler Gauge Figure 4. Checking Valve Clearance VALVE MECHANISM REMOVAL 1. Remove rocker arm cover as outlined, preceding. IMPORTANT: Place rocker arms, rocker arm fulcrums and push rods in a rack so that they may be reinstalled in same location. 2. Remove rocker arm bolts, fulcrums, rocker arms and push rods. CLEANING and INSPECTION 1. Clean parts in solvent and dry with compressed air. 2. Inspect each rocker arm for wear in area where push rod, valve stem and fulcrum contact rocker arm. Replace excessively worn rocker arms. 3. Check push rod ends and fulcrum for excessive wear. Replace badly worn parts. 4. Check push rods for bent condition. a - Torque Wrench b - Push Rods in Lifter Socket Figure 5. Valve Mechanism Installation 977R1 MERCRUISER ENGINE - 5C-5 INSTALLATION CAUTION: Push rods may become bent, if the 1. Install push rods. Be sure that push rods seat in lifter following rocker arm torque procedure is not com socket. (Figure 5) pleted. 2. Lubricate fulcrums and rocker arms with Molv-Kote (C-92-55049) or Engine Oil Supplement (C-92-63283). Install rocker arms, fulcrums and rocker arm fastening bolts. DO NOT tighten bolts at this time. 3. With piston at TDC, torque rocker arm bolts (Figure 5) for NOTE: Torquing of rocker arm bolts (Step 3) and that cylinder to specifications. Turn engine crankshaft for checking valve clearance (preceding) are both done with proper piston position for each cylinder and torque all valve in closed position. Time can be saved by completing rocker arm bolts to specifications. both of these steps at the same time. 4. Install rocker arm cover as outlined, preceding. HYDRAULIC VALVE LIFTERS REMOVAL DISASSEMBLY 1. Remove rocker arm cover as outlined, preceding. NOTE: Lifters can be disassembled, cleaned and re2. Remove valve mechanism, preceding. installed. If any parts are worn, lifter must be replaced as 3. Remove 4 bolts with "0 " rings and remove side cover. an assembly. 4. Lift out lifters with a pointed tool inserted in lock ring 1. Use small screwdriver or needle-nose pliers to remove groove. (Figure 6) Place lifters in order so that lifter will be lockring. (Figure 7) reinstalled in same location. 2. Lightly tap top end of lifter assembly on flat surface to remove push rod cup, plunger/check valve assembly and spring. (Figure 8) 09801 a - Lockring c b- Push Rod Cup de Figure 8. Lifter Components CLEANING and INSPECTION 1. Thoroughly clean all parts in cleaning solvent and dry them with compressed air. 2. Carefully inspect all parts for wear, pitting, scoring or galling. If any parts are damaged or worn, entire lifter assembly must be replaced. If outside of lifter body is scuffed or worn, inspect cylinder block lifter bore. If bottom of lifter is scuffed or worn, inspect camshaft lob' If push rod seat is scuffed or worn, inspect push rod. REASSEMBLY IMPORTANT: Work in clean area. 1. Inject engine oil in lifter body to approximately !4-full. 09805 Plunger/Check Valve Assembly Plunger Spring Lifter Body a - Lifter b - Pointed Tool Figure 6. Removing Hydraulic Valve Lifters a - Lockring b- Lifter Assembly c - Small Screwdriver Figure 7. Removing Lockring 5D-6 - MERCRUISER ENGINE 2. Set plunger spring in lifter body. (Figure 8) 3. Place plunger assembly (check valve end down) in lifter body. (Figure 8) 4. Use small punch to unseat check ball (located in bottom of plunger assembly) and push plunger (compressing spring) until top of plunger is below hole in side of lifter body. (Figure 9) Now insert small punch through side hole to hold plunger in position. 5. Remove punch from check ball and position push rod cup in lifter body. 6. Install lockring in groove and remove punch from lifter body side hole. INSTALLATION a - Lockring c - Lifter Body 1. Lubricate all camshaft lobes, lifter bores and entire lifter b- Push Rod Cup d - Small Punches with Moly-Kote or Engine Oil Supplement. Figure 9. Assembling Lifter 2. Replace lifter into lifter bore from which it was removed. surface. Install cover, using new gasket and new "0 " rings 3. Install valve mechanism as outlined, preceding. on cover attaching bolts. 4. Remove all oil from cylinder block side cover gasket 5. Install rocker arm cover as outlined, preceding. VALVE SPRING, RETAINER or STEM SEAL REPLACEMENT (with CYLINDER HEAD INSTALLED) 1. Remove rocker arm cover as outlined (see "Index"). 2. Remove spark plug of cvlinder(s) from which valve spring will be removed. 3. Remove rocker arm bolt, fulcrum, rocker arm and push rod of applicable valve(s). 4. Position piston of applicable cylinder at top dead center to prevent valve from dropping out of valve guide. 5. Install an air line with adaptor in spark plug hole (Figure 10) and turn on air pressure. 6. Install suitable bolt (from where rocker arm bolt was removed) and position compressor tool as shown in Figure 09781 a - Retainer Locks c - Valve Spring e - Valve b • Spring Retainer d - Seal Figure 11. Valve and Related Parts 10. Compress valve spring and remove retainer locks. Remove tool, then remove retainer, valve spring and seal. (Figure 11) 7. Install new valve stem seal. Place spring in position over valve and install valve spring retainer. Compress valve spring and install spring retainer locks. (Figure 10) Remove compressor tool and bolt. NOTE: If new spring was installed, check installed spring height. Refer to "Valve Spring Inspection" (see "Index"). 09819 8. Remove air line and adaptor. Install spark plug and wire. a - Tool b- Air Line Adaptor c - Suitable Bolt 9. Install valve mechanism as outlined (see "Index"). Figure 10. Compressing Valve Spring 10. Install rocker arm cover as outlined (see "Index"). 977R1 MERCRUISER ENGINE - 5C-7 CYLINDER HEAD and VALVES CYLINDER HEAD REMOVAL 1. Remove intake and exhaust manifold. See "Index" for instructions. 2. Remove rocker arm cover and valve mechanism per instructions, preceding. 3. Disconnect spark plug high tension wires and remove spark plugs and coil bracket. 4. Disconnect water hose. 5. Remove fastening bolts, then remove cylinder head assembly and gasket. 06015 a - Check Diagonally b- Check Diagonally VALVE REMOVAL c - Check Across Center 1. Remove cylinder head as outlined, preceding. Figure 13. Typical Cylinder Head Flatness 2. Clean carbon out of cylinder head combustion chambers before removing valves (to prevent damaging valve seats). gasket leaks. (See "Specifications" Section 8.) If necessary Refer to "Cleaning and Inspection", following. to refinish cylinder head gasket surface, do not plane or 3. Compress valve springs (Figure 12) with conventional valve grind off more than .010" (0.25mm). spring compressor and remove retainer locks. 7. Measure valve stem clearance (Figure 14) as follows: 4. Remove spring compressor tool, spring retainer, valve a. Clamp dial indicator on one side of cylinder head spring, valve stem seal and valve. Identify all valves to rocker arm cover gasket rail, locating indicator so that reinstall in same location. movement of valve stem from side-to-side (crosswise to 5. Repeat Steps 3 and 4 (above) to remove each valve. head) will cause direct movement of indicator stem. Indicator stem must contact side of valve stem just above valve guide. (Figure 14) b. With valve head dropped about 1/16" (1.6mm) off valve seat, move valve stem from side-to-side, using light pressure to obtain clearance reading. c. If clearance exceeds specifications, it will be necessary to ream valve guides for next oversize valve(s), as follows (Figure 15): (1) Valve guide(s) to be reamed must be refinished before doing any checking or refacing of valve seat. (2) After guide is refinished, seat also must be refaced to match guide. (3) Always use reamers in sequence (starting with smallest oversize reamer) when going from standard valve stem to an oversize. (4) Remove sharp corner (inside diameter) from top of valve guide, using a scraper or other appropriate tool. a - Valve Spring Compressor Tool c - Valve Stem b- Valve Spring d - Spring Retainer e - Retainer Locks Figure 12. Removing and/or Installing Valves CYLINDER HEAD CLEANING, INSPECTION and RECONDITIONING 1. With valves installed to protect valve seats, remove deposits from combusion chambers and valve heads with a scraper and wire brush. 2. Clean cylinder head gasket surfaces with a scraper. 3. .After removing valves, clean valve guide bores with valve guide cleaning tool. Use cleaning solvent to remove dirt, grease and other deposits. 4. Clean all bolt holes. 5. Check cylinder head for cracks and inspect gasket surface for burrs and nicks. Replace head if cracked. 6. Check cylinder head for flat gasket surface (Figure 13), particularly if cylinder head was removed because of 5C-372 - MERCRUISER ENGINE a - Valve Stem b-Dial Indicator c - Valve Guide Figure 14. Checking Valve Stem Clearance 977 R1 a - Reamer b-Valve Guide Figure 15. Reaming Valve Guides (5) Qean head assembly thoroughly to be sure that all metal filings are removed. 8. Check valve seat for runout (Figure 16), as follows: a. Install accurate gauge on tool positioned in valve stem guide. b. Follow instructions of gauge manufacturer. If runout exceeds wear limit, reface valve and valve seat. Refer to Step 9-b (following) for valve seat refacing. 373 06017 a • Gauge b-Valve Stem Guide (Hidden) c - Valve Seat Figure 16. Checking Valve Seat Runout 9. Check valve seat width (Figure 17), as follows: a. Use scale with small increments and measure valve seat width. (Figure 17) b. Reface valve seat(s), if width is not within specifications, as follows (Figure 18): (1) Closely coordinate refacirig valve seat with refacing valve face so that finished seat and valve face are concentric, and specified interference fit will be maintained. This is important so that valve and seat have compression-tight fit. Be sure that refacer grinding wheels are properly dressed. (2) Grind valve seats to correct angle (see "Specifications" Section 8). Remove only enough stock to clean up pits and grooves or to correct valve seat runout. (3) Finished valve seat must contact appropriate center of valve face. Apply ink (with felt tip pen) to refinished valve face. Install valve and rotate with light pressure. Remove valve and check seat contact. If seat contacts center of valve face, contact is satisfactory. If seat contact is at top edge of valve face, lower the valve seat, using 30° angle grinding wheel. If seat contact is at bottom edge of valve face, raise the valve seat, using 60° angle wheel. (4) .After seat has been refaced, recheck seat width. If width exceeds maximum limit, remove enough stock from top edge (use 30° wheel) and/or bottom edge (use 60° wheel) of seat to reduce width to specifications. Figure 17. Checking Valve Seat Width (5) If valve and/or seat has been refaced, check clearance between rocker arm seat and valve stem. Refer to "Valve Clearance" (see "Index"). VALVE CLEANING, INSPECTION and RECONDITIONING 1. Clean deposits from valve head and stem, being careful not to damage valve face. 2. Closely coordinate valve refacing operation with valve seat refacing operations so that finished angles of valve face and a - Valve Seat Width b - Valve Angle Figure 18. Refacing Valve Seat 977R1 MERCRUISER ENGINE - 5C-9 valve seat will meet specifications and provide com pression-tight fit. Be sure that refacer grinding wheels are properly dressed. 3. See Section 8, "Specifications", for valve face angle. Remove only enough stock to correct runout or to clean up pits and grooves. If edge of valve head is less than 1/32" (0.8mm) thick after grinding, replace valve. 4. If valve and/or seat has been refaced, check clearance between rocker arm seat and valve stem. Refer to "Valve Clearance" (see "Index"). VALVE SPRING INSPECTION 1. Check springs for correct pressure at specified spring lengths with Tool J-8056. (Figure 19) Follow tool manufacturer instructions. 2. Replace any spring not within specifications. Figure 19. Checking Valve Spring Pressure 3. Check each spring for "square". Stand spring (closed coil end downward) and steel square (Figure 20) on flat surface. Slide spring up to square. 4. Revolve spring slowly and observe space between top coil of spring and square. Out-of-square limits are 5/64" (2mm). 5. Measure assembled height of valve spring from surface of cylinder head spring seat to underside of spring retainer. (Figure 21) If assembled height is greater than specifications, install spacer(s) below spring to reduce height to recommended dimension. DO NOT overshim. VALVE INSTALLATION 1. Lubricate valve stem and valve stem guide with Engine Oil Supplement. Install each valve in port from which it was removed or to which it was fitted. 2. Install new stem seal on valve. 3. Install valve spring over valve, then install spring retainer. (Figure 11, preceding) 4. Compress spring (using compressor tool) and install re5C- 10 - MERCRUISER ENGINE 06018 a - Valve Spring Closed Coil End b- Max. 5/64" Figure 20. Checking Valve Spring Squareness tainer locks. (Figure 12, preceding) Make sure that locks are positioned properly in valve stem groove. 5. Measure valve spring assembled height. Refer to "Valve Spring Inspection", preceding. CYLINDER HEAD INSTALLATION 1. Be sure that all gasket surfaces are clean. 2. Position cylinder head gasket on cylinder block with word "FRONT" (stamped on gasket) toward front of engine and facing down toward block. Place cylinder head on top of gasket. 3. Coat threads and underside of bolt head with Perfect Sea. and install cylinder head bolts. Torque bolts as follows: CAUTION: Failure to properly torque cylinder head bolts will result in very short head gasket life. Cylinder head bolt holes (located in cylinder block) must be free of water or oil when installing cylinder head fastening bolts. Block failure may occur from hydraulic pressure buildup while torquing cylinder head bolts. a. Torque cylinder head bolts to 55 ft. lbs. (7.6mkg) in sequence shown in Figure 22. b. Using same sequence, retorque bolts to 90 ft. lbs. (12.4mkg). „ a - See Spec.f .cat.ons Figure 21. Measuring Spring Height 977 R1 c. Using same sequence, retorque bolts to 130 ft. lbs. (18mkg). d. After engine has reached maximum operating temperature retorque cylinder head bolts to 130 ft. lbs., using same sequence. 4. Connect water hose, install spark plugs, spark plug high tension wires and coil bracket. a - Front 5. Install valve mechanism, rocker arm cover, intake and Figure 22. Cylinder Head Torquing Sequence exhaust manifolds (see "Index"). 977R1 MERCRUISER ENGINE - 5C-11 ALTERNATOR ROTOR REMOVAL 1. Remove front engine mount assembly (if applicable). 2. Remove bolt from center of rotor (Figure 1) and remove washer from bolt. 09808 09814 a - Tool Figure 2. Removing Alternator Rotor a - Alternator Rotor b - Center Bolt c - Washer Figure 1. Alternator Rotor 3. Install Tool J-6978-04 and remove rotor assembly. (Figure 2) Use grease on tapered end of tool. INSTALLATION 1. Lubricate lip of oil seal and rotor surface (where oil seal rides) with Multipurpose Lubricant. 2. Check that rotor locating key is properly installed in crankshaft groove. 3. Lubricate crankshaft end and inside diameter of rotor assembly with Chicago Manufacturing and Distribution Co. anti-scoring, extreme pressure Lubricant No. 3 or equivalent. 4. Position rotor assembly onto crankshaft, aligning key slot in rotor with key located on crankshaft. 5. Install Tool J-21058-8 into crankshaft end. Hold tool center shaft from turning and turn large nut to install rotor 1 (Figure 3) until rotor bottoms out. 6. Install rotor fastening bolt and washer and torque bolt to a - Alternator Rotor b- Installation Tool Figure 3. Installation of Alternator Rotor specifications. TESTING Refer to Section 3C."Alternator". REMOVAL STATOR 1. Remove alternator rotor as outlined, preceding. 2. Disconnect stator electrical wires from rectifier and remove stator wire harness from clamp. (Figure 4) 3. Remove 5 stator fastening screws and remove stator. (Figure 4) INSTALLATION 1. Position stator onto front cover with output wires toward recess cast in cover. (Figure 10) 2. Apply Perfect Seal on screw threads, install screws (Figure 4) and torque to specifications. 3. Install stator wire harness in clamp and reconnect stator electrical wires to rectifier. (See Section 3E for proper electrical connections.) 4. Install alternator rotor as outlined, preceding. 977 R1 5C-12 - MERCRUISER ENGINE a - Stator Fastening Screws b- Stator Assembly c - Wire Harness Clamp d- Front Cover Recess e - Stator Wire Harness Figure 4. Stator Assembly on Engine a - Stator Fastening Screws b- Stator Assembly c - Wire Harness Clamp d- Front Cover Recess e - Stator Wire Harness Figure 4. Stator Assembly on Engine FRONT COVER and/or WATER PUMP SHAFT and FRONT COVER OIL SEALS REMOVAL IMPORTANT: Oil pan gasket must be replaced whenever front cover is removed. (Refer to "Oil Pan Removal- Installation".) 1. Remove front engine mount (if applicable). 2. Remove alternator rotor and stator as outlined, preceding. 3. Remove water pump impeller cover and pump impeller. (Figure 5) Impeller nut is left-hand thread. 4. Remove remaining front cover fastening bolts and cover. 5. Drive out both oil seals. CLEANING and INSPECTION 1. Clean gasket surface of cover arid cylinder block with a scraper. a - Tool c - Front Cover Assembly b - Water Pump Shaft Oil Seals d - Arbor Press Figure 6. Typical Oil Seal Installation 2. Clean parts in solvent and dry with compressed air. If oil seals are not being replaced. DO NOT allow solvent to remain on oil seals for any length of time. 3. Inspect oil seals for wear, tears, roughness and proper spring position. If oil seal serviceability is doubtful, replace oil seals. 4. Inspect surface of shaft(s) where oil seal lips contact shaft. Any groove in shaft in this area requires oil seal(s) and shaft replacement. INSTALLATION 1. Apply Perfect Seal to outside diameter of water pump shaft oil seals and front cover oil seal. DO NOT allow sealer on lip of seals. IMPORTANT: Support underside of cover when installing oil seals. 2. Both water pump seal lips face water side or front of engine. First water pump seal is pressed in until it bottoms out: second seal is pressed in until even with cover surface. (Figure 6) MERCRUISER ENGINE - 5C-13 a • Front Cover b - Water Pump Impeller c - Impeller Nut d - Impeller Cover Gasket Mating Surface e - "J" Clamp Figure 5. Removing or Installing Front Cover 977R1 3. Fill space between water pump oil seals with Multipurpose 9. Install water pump impeller, flat washer against impeller Lubricant. and onto larger diameter of shaft (use grease to hold 4. Install front cover crankshaft seal with seal lip facing in or washer in place), cupped washer (concave side toward toward engine block. Press seal in until it bottoms-out. impeller) and nut. (Figure 5) Torque left hand threads 5. Lubricate seal lip with Multipurpose Lubricant. nut to specifications. 6. Lubricate crankshaft end and water pump shaft with 10. Install water pump cover, using new gasket. Apply Perfect Multipurpose. Seal to fastening bolts' threads and torque to specifi 7. Position new front cover gasket over dowel pin on front of cations. cylinder block. 11. Install alternator rotor and stator as outlined, preceding. 8. Position front cover over gasket. Apply Perfect Seal on threads of front cover fastening bolts and install bolts. 12. Reinstall front engine mount (if applicable). Torque bolts to specifications. "J" clamp location is 13. Make sure that oil pan gasket has been replaced per shown in Figure 5. instructions, preceding. (See "Index".) TIMING CHAIN and SPROCKETS REMOVAL 1. Drain cooling system and crankcase. 2. Remove alternator rotor, stator and front cover as outlined, preceding. (See "Index".) 3. Check timing chain deflection. Refer to "Timing Chain Deflection", following. 4. Crank engine until timing marks on sprockets are positioned as shown in Figure 7. 5. Remove chain tensioner and camshaft fastening screws. (Figure 7) 6. Slide both sprockets and timing chain forward and remove as an assembly. a - Timing Marks e - Timing Chain b- Crankshaft Sprocket f - Chain Tensioner c - Camshaft Sprocket g - Sprocket Locating Pin . d - Sprocket Fastening Screws h - Sprocket Locating Key j Figure 7. Timing Chain and Sprockets I TIMING CHAIN DEFLECTION 1. Rotate crankshaft in clockwise direction (as viewed from 3. Rotate crankshaft in opposite direction to take up slack on front) to take up slack on left side of chain. right side of chain. Force left side of chain out with fingers 2. Establish a reference point on cylinder block and measure and measure distance between reference point and chain. from this point to chain. Deflection is difference between the 2 measurements. If deflection exceeds 1" (25.4mm), replace timing chain and inspect sprockets and tensioner for abnormal wear. CLEANING and INSPECTION 1. Clean all parts in solvent and dry with compressed air. 2. Inspect chain for worn or broken links. 3. Inspect sprockets for cracks, scores, nicks and worn or damaged teeth. 4. Inspect chain tensioner for wear or damage. If chain deflection is within specifications and tensioner does not touch chain, replace tensioner. 5. Tensioner, that is worn beyond normal groove wear (Figure 8), must be replaced. 6. Place tensioner on flat surface. Demension between flat surface and top (highest point) of tensioner must be 1&' (32mm) or higher. INSTALLATION a - Normal Groove Wear b- Excessive Wear Area j Positio n cranksh af t and camshaft with locating pin and Figure 8. Chain Tensioner Wear key facing as shown in Figure 13. 5C-14 - MERCRUISER ENGINE 977 R1 2. Position sprockets in timing chain and simultaneously install sprockets (with chain) on camshaft and crankshaft. Timing marks must be located as shown in Figure 7. Check timing mark location, using a straight edge. 3. Install camshaft fastening screws and torque to specifications. 4. Install chain tensioner. Liberally lubricate chain, chain tensioner and sprockets with engine oil. 5. Install front cover, stator and alternator rotor as outlined, preceding. (See "Index".) 6. Fill cooling system and crankcase to proper levels. ENGINE COUPLER and/or FLYWHEEL REMOVAL 1. Remove engine from boat. (Refer to Section 2.) 2. Remove all attaching parts from flywheel housing and remove flywheel housing. 3. Remove coupler by disconnecting retainingwashers. 4. Remove flywheel. INSPECTION Engine Coupling nuts and 1. Check coupling spline for wear. Coupling wear is caused by- insufficient lubrication at time of installation. 2. Inspect hub bond. Bonding, that shears or pulls loose from hub center, indicates engine/drive misalignment. Flywheel Inspect ring gear for worn, chipped or cracked teeth. If teeth are damaged, replace flywheel. INSTALLATION 1. Position flywheel (aligning offset holes) on crankshaft studs. 2. Position engine coupler on studs in same manner and install washers and locknuts. Torque nuts to specifications with torque wrench and Adaptor (C-91-35547). 3. Install flywheel housing and housing attaching parts. 4. Lubricate coupler splines with Multipurpose Lubricant and install engine in boat. (Refer to Section 2.) OIL PAN REMOVAL 1. Drain crankcase oil. 2. Remove oil level dipstick and dipstick tube. 3. Remove attaching bolts and washers and remove oil pan. CLEANING and INSPECTION 1. Remove any dirt or metal particles from inside of pan. 2. Scrape all gasket material from gasket surface. 3. Wash pan in solvent and dry thoroughly. 4. Check pan for cracks, holes, damaged drain plug threads and damaged gasket surface. 5. Repair any damage or replace pan if repairs cannot be made. INSTALLATION IMPORTANT: Timing cover must be installed before installation of oil pan. 1. Coat cleaned gasket surfaces of block and oil pan with thin coat of Perfect Seal. Apply sealer thicker in area on block 09792 a - Rear Main Cap Seals b - Timing Cover Mating Surface Figure 9. Oil Pan Installation where timing cover meets block and on rear main cap seals. (Figure 9) 2. Position new gasket on cylinder block gasket surface. 3. Carefully position oil pan and install attaching bolts. Torque bolts to specifications from center outward in each direction. Retorque bolts a second time. OIL PUMP REMOVAL 1. Remove oil pan as outlined, preceding. 2. Remove bolts from oil pump pickup tube clamps. 3. Remove oil pump attaching bolts and remove oil pump assembly. DISASSEMBLY 1. Remove 2 bolts and pickup tube, retaining flange and "0 " ring. 2. Remove 4 screws and lockwasher and remove cover from pump body. 976 MERCRUISER ENGINE - 50-15 3. Inner and outer rotors each have identification marks on one side. After installation, these 2 points must appear on the same side. Remove inner and outer rotor. 4. Remove welch plug, spring and valve. CLEANING and INSPECTION 1. Wash all parts in solvent. Clean inside of pump housing and pressure relief valve chamber with a brush. Be sure that all dirt and metal particles are removed. Dry parts thoroughly with compressed air. 2. Check inside of pump housing, outer rotor and inner rotor for damage or excessive wear. 3. Replace cover if rotor mating surface on cover is worn, scored or grooved. 4. Measure outer race to housing clearance [min. .001" to .0125"(,025mm to ,318mm)]. (Figure 10) 5. With rotor assembly installed in pump housing, place a straight edge over rotor assembly and pump body. (Figure 11) Use a feeler gauge and measure clearance (rotor end play) between straight edge and rotor [min. .001" to max. .005" (,025mm to .127mm)]. 6. Check drive shaft to pump housing clearance by measuring —« 06025 a - Feeler Gauge c - Outer Race b- Housing d- Identification Marks Figure 10. Checking Outer Rotor to Housing Clearance 06099 a - Straight Edge b - Feeler Gauge Figure 11. Checking Rotor End Play 5C-16 - MERCRUISER ENGINE a-Welch Plug d - Pump Housing b-Relief Valve Spring e - Outer Rotor c - Relief Valve Plunger f - Inner Rotor Figure 12. Oil Pump Assembly g - Cover h - Lockwasher (4) i - Screw (4) a - Oil Pump Alignment Tool b-Tightening Pump Fastening Bolts c - Oil Pump Figure 13. Installing Oil Pump Assembly OD of shaft and ID of housing cavity [min. .0015" to max. .0025" (,038mm to .064mm)]. 7. Inspect relief valve piston for scores and free operation in bore. 977 R1 8. Inspect relief valve spring for collapsed or damaged condition. REASSEMBLY Oil pump assembly is shown in Figure 12. 1. Oil all parts thoroughly. 2. Install oil pressure relief valve plunger, spring and new welch plug. Plug should be installed flush with pump housing. 3. Install outer and inner rotor and shaft assembly. Be sure that dot (identification mark) on outer and inner rotor is facing the same direction. 4. Install cover and torque cover attaching screws to specifications. 5. Position "0 " ring and install pickup tube, its retaining flange (flat surface against pump housing) and 2 fastening bolts. Torque bolts to specifications. INSTALLATION 1. Position oil pump onto cylinder block and loosely install fastening bolts. 2. Install Oil Pump Alignment Tool (C-91-75691) thru distributor installation hole and into oil pump drive. (Figure 13) 3. Torque oil pump fastening bolts to specifications. 4. Fasten oil pump pickup tube to cylinder block in 2 places, using clamps and fastening screws. Coat threads with Perfect Seal and torque screws to specifications. 5. Install oil pan as outlined, preceding. OIL SEAL (REAR MAIN) REMOVAL 1. Remove flywheel, using instructions, preceding. 2. Pry old oil seal from cylinder block assembly, using appropriate tool. Take care that crankshaft seal surface is not scratched or damaged by tool. a - Mallet b-Tool Figure 14. Installing Rear Main Oil Seal CLEANING and INSPECTION 1. Clean oil seal cavity in cylinder block. 2. Inspect area on crankshaft (where oil seal rides) for groove, nicks or pitting condition. If necessary, clean up crankshaft surface with No. 320 grit polishing cloth and engine oil. Replace crankshaft if damage is too great. Too much surface removed from crankshaft seal surface will cause oil leak. 3. Always install new oil whenever engine is disassembled. DO NOT reinstall used seals. INSTALLATION IMPORTANT: Rear main bearing cap must be properly installed before installation of oil seal. 1. Apply Perfect Seal to rear oil seal housing. Sealant must not be applied on crankshaft seal surface. 2. Lubricate oil seal lip and crank surface with Multipurpose Lubricant. 3. Drive seal (with lip facing inward) into cylinder block cavity until it bottoms-out. (Figure 14) Use Installer Tool (J-26817). Take care not to cock seal during installation. MERCRUISER ENGINE - 5D-17 CAMSHAFT MEASURING LOBE LIFT NOTE: Procedure is similar to checking valve timing. If improper valve operation is indicated, measure lift of each push rod in consecutive order and record the readings. 1. Remove valve mechanism as outlined. 2. Position indicator point on push rod. (Figure 1) 3. Rotate crankshaft slowly in direction of rotation until lifter is on lowest position of cam lobe. 4. Set dial indicator on zero, then rotate crankshaft slowly until push rod is in fully-raised position. 5. Compare total lift recorded from dial indicator with specifications in Section 8. 6. Continue to rotate crankshaft until indicator reads zero (0). This will be a check on accuracy of original indicator reading. a - Dial Indicator b- Push Rod Figure 1. Measuring Camshaft Lobe Lift (Typical Cylinder Head) 01689 a - Dial Indicator b- "V" Block (One Not Shown) Figure 2. Checking Camshaft Alignment 7. If camshaft readings for all lobes are within specifications, remove dial indicator assembly. 8. Install and adjust valve mechanism as outlined. REMOVAL 1. Remove valve lifters as outlined. 2. Remove engine front cover as indicated. 3. Remove fuel pump as outlined. 4. Align timing gear marks, then remove timing chain and sprockets, as explained. 5. Pull camshaft out thru front of block. NOTE: Support camshaft carefully when removing to protect camshaft bearing surface. INSPECTION 1. Measure camshaft bearing journals with a micrometer for out-of-round condition. If journals exceed out-of-round specifications, replace camshaft. 2. Check camshaft for alignment with "V" blocks and dial indicator (Figure 2) for exact amount that camshaft is out-of-true. If out more than .002" (,051mm) on dial indicator, replace camshaft. 3. Inspect camshaft sprocket and thrust plate for wear or damage. Measure camshaft end play. (Figure 3, following) 5C-18 - MERCRUISER ENGINE 977 R1 CAMSHAFT GEAR REPLACEMENT Refer to 'Timing Chain and Sprockets" (see "Index"). INSTALLATION 1. Install camshaft in engine block, being careful notdamage camshaft bearing surface or camshaft. thrust plate and torque screws to specifications. 2. Install timing chain and sprockets as outlined"Index"). 3. With sprockets and timing chain properly installed, check camshaft end play. Use dial indicator on face of camshaft sprocket (Figure 3) and move camshaft in-and-out while recording end play. If not within specifications, replace thrust plate and/or sprocket. 4. Install fuel pump as outlined. 5. Install engine front cover as explained. 6. Install valve lifters as outlined. a - Dial Indicator b- Indicator Registering Point c - Camshaft Sprocket Figure 3. Checking Camshaft End Play CAMSHAFT BEARINGS to Install (see 09902 Camshaft rotates directly in aluminum (cylinder block) bores. 2.2510" (57.137mm to 57.175mm) diameter and bearings can If bore surface is damaged, bore can be enlarged 2.2495" to be installed. Refer to Parts Manual for bearings. If one bore surface is damaged, all bores should be enlarged and bearings installed. Bearing Installation Kit (T65L-6250-A) should be used. Typical installation is shown in Figure 4. Hole in bearing must align with hole in block. Follow tool manufacturer's installation instructions. a-Pulling Nut e - Backup Nut b-Thrust Bearing f - Puller Screw c • Expanding Mandrel g - Puller Plate d - Expanding Collet h - Puller Screw Extension i - Camshaft Bearing Figure 4. Typical Camshaft Bearing Installation CRANKSHAFT Crankshaft can be removed while engine is disassembled for CLEANING and INSPECTION overhaul or without complete disassembly. 1. Wash crankshaft in solvent and dry with compressed air. 2. Measure dimensions of main bearing journals and crank- REMOVAL pins with a micrometer for out-of-round, taper or under- size (see "Specifications" Section 8). 1. Remove flywheel housing, coupler and flywheel. 3. Check crankshaft for run-out by supporting at front and 2. Remove spark plugs. rear main bearing journals in "V " blocks and check at 3. Remove oil pan and oil pump. front and rear intermediate journals with a dial indicator 4. Remove front cover and timing chain. (see "Specifications"). 5. Check connecting rod caps for cylinder number identifi4. Replace or recondition crankshaft if not within specification. If necessary, mark caps. cations. 6. Remove connecting rod caps and push pistons to top of bores. INSTALLATION 7. Remove main bearing caps and rear main oil seal and lift crankshaft out of cylinder block. 1. Check bearing clearance as outlined, following. 8. Remove main bearings from cylinder block and main 2. Install bearings in cylinder block and main bearing caps, bearing caps. then lubricate bearing surface with engine oil. Thrust 977R1 MERCRUISER ENGINE - 5C-19 seals (one each side) to extend .015" from bottom (oil pan side) of bearing cap. 8. Install 4 other bearing caps with cast arrow pointing toward front of engine (Figure 8) and cast numbers i' 09877 a - Rear Main Bearing Cap Side Oil Seals (2) b- Bearing c - Rear Main Bearing Cap d- Protrude .015" (.38mm) Figure 5. Rear Main Bearing Side Seal Installation bearing is located at No. 3 position. Make sure that tab (located on back of bearings) is positioned in slot (located in cylinder block and bearing caps). 3. Stretch rear main side oil seal slightly and install in groove on each side of rear main. (Figure 5) Seal end must protrude .015" (0.38mm) from block side of bearing cap. Leave ample amount of seal extend from bottom (oil pan side) of bearing cap which will be cut to .015" protrusion after bearing cap installation. 4. Apply Perfect Seal to cylinder block in area where rear main bearing cap mates with block. DO NOT apply sealer bevond centerline of bolt holes toward crankshaft. (Figure 6) a - Area on Which Sealer Is Applied b - Area to Which Sealer Is NOT Applied (One Side Hidden) c - Bolt Hole Centerline (One Each Side) Figure 6. Applying Sealer to Cylinder Block 5. Apply Perfect Seal to outside face of side seals on rear cap to facilitate installation. Install rear cap, being careful that side seal does not move up cap groove. With rear cap installed, seal end still must protrude from block side of cap. 6. Install cap fastening bolts and torque to specifications. 7. Use .015" feeler gauge as guide (Figure 7) and cut side a - Feeler Gauge b- Seal (One Each Side) c - Knife Figure 7. Cutting Rear Main Side Seals a - Correct Alignment d - Bearing Cap b- Alignment Not Correct e - Crankshaft c - Crankshaft End Play f - Cylinder Block Figure 9. No. 3 Bearing Cap Installation 5C-20 - MERCRUISER ENGINE 977 R1 their respective location. Torque all bearing cap bolts (except No. 3) to specifications. 9. To prevent misalignment of thrust bearing (located at No. 3 bearing cap), pry crankshaft toward front of engine, then toward rear of engine. With crank in this position, torque bolts to specifications. Correct bearing alignment is shown in Figure 9. 10. Check crankshaft end play with feeler gauge between thrust bearing and crankshaft. 11. Check that crankshaft turns freely with little effort. If crank does not turn freely, bearing clearances, bearing and journal diameters and crank straightness should be checked. 12. Reinstall connecting rods. Refer to "Connecting Rod and Piston Installation", following. 13. Install front cover, oil pump, oil pan. spark plugs, flywheel, coupler and flywheel housing. Refer to "Index" for particular installation procedures. 976 MERCRUISER ENGINE - 50-21 MAIN BEARINGS Main bearings are precision insert type and do not utilize shims for adjustment. If clearances are found to be excessive, a new bearing (both upper and lower halves) is required. Bearings are available in standard size and .002" and .020" (0.051mm to 0.51mm) undersize. When a production standard crankshaft journal cannot be precision-fit, it then is ground .002" undersize on all main journals (.002" will be stamped on crankshaft front counterweight, as shown in Figure 4, following). REMOVAL Refer to "Crankshaft Removal", preceding. Place used bearings so that they can be installed in same location from where thev were removed. CLEANING and INSPECTION Clean bearing inserts and caps thoroughly in solvent and dry with compressed air. DO NOT scrape gum or varnish deposits from bearing shells. Inspect each bearing carefully. Replace bearings with scored, chipped or worn surface. In general, lower half of bearing shows greater wear and most distress from fatigue. If lower half shows evidence of wear or damage, replace both upper and lower halves. Never replace one half without replacing other half. Typical bearing failures are shown in Figure 1. following. 06005 a - Scratched by Dirt d - Bright Polished Sections (Improper Seating) f - Radius Ride b- Dirt Embedded into Bearing Material e - Overlay Gone from Entire Surface g - Craters or Pockets (Fatigue Failure) c - Overlay Wiped Out (Lack of Oil) (Tapered Journal) Figure 1. Typical Bearing Failure CHECKING CLEARANCE To obtain accurate results, use Plastigage (or its equivalent), a wax-like plastic material that will compress evenly between bearing and journal surfaces without damaging either surface. With engine upside-down, crankshaft will rest on upper bearings, and total clearance can be measured between lower C ' bearing and journal. NOTE: To assure proper seating of crankshaft, torque all bearing cap bolts as specified. In addition, before checking fit of bearings, wipe surface of crankshaft journal and face and back of bearing clean of oil. 1. With oil pan and oil pump removed, and starting with rear main bearing, remove bearing cap and wipe oil from journal and bearing cap. 5C-22 - MERCRUISER ENGINE 2. Place piece of gauging plastic the full width of bearing (parallel to crankshaft) on journal. (Figure 2) CAUTION: DO NOT rotate crankshaft while the gauging plastic is between bearing and journal. 3. Install bearing cap and torque retaining bolts evenly to specifications. 4. Remove bearing cap. Flattened gauging plastic will be found adhering to either bearing shell or journal. 5. Edge of gauging plastic envelope has a graduated scale (ir thousandths of an inch). Without removing gauging plastic, measure its compressed width (at widest point) with graduations on gauging plastic envelope. (Figure 3) NOTE: Normally, main bearing journals wear evenly and are not out-of-round. However, if a bearing is being fitted 977 R1 to an out-of-round journal [.001" (,025mm) max.], be sure to fit to maximum diameter of journal. If bearing is fitted to minimum diameter, and journal is out-of-round .001", interference between bearing and journal will result in rapid bearing failure. If flattened gauging plastic tapers toward middle or ends, there is a difference in clearance that indicates taper, low spot or other irregularity of bearing or journal. Be sure to measure journal with a micrometer, if flattened gauging plastic indicates more than .001 " difference. 6. If bearing clearance is within specifications, bearing insert is satisfactory. If clearance is not within specifications, replace insert. Always replace both upper and lower insert as a unit. 7. A standard or .002" (0.051mm) undersize bearing may produce proper clearance. If not, regrind crankshaft journal for use with next undersize bearing. Reinstall bearing cap. Figure 3. Measuring Gauging Plastic 8. Proceed to next bearing. After all bearings have been checked, rotate crankshaft so that no excessive drag exists. 9. After bearing fit is correct, remove crankshaft and oil bearing surfaces and reinstall crankshaft. Refer to "Crankshaft Installation", preceding. MAIN BEARING REPLACEMENT 1. Remove and inspect crankshaft. 2. Remove main bearings from cylinder block and main bearing caps. 3. Coat bearing surfaces of new, correct-size main bearings with oil and install in cylinder block and main bearing caps. Check clearance outlined. 4. Install crankshaft. (See "Crankshaft Installation", preceding.) CONNECTING ROD BEARINGS Connecting rod bearings are precision insert type and do not 4. Measure crankpin for out-of-round or taper with a micromutilize shims for adjustment. DO NOT FILE RODS OR ROD eter. If not within specifications, replace or recondition CAPS. If clearances are found to be excessive, a new bearing is required. Bearings are available in standard size and .002" (0.051mm) undersize for new and used standard size crankshaft and in .020" (0.51mm) undersize for reconditioned crankshafts. When a production standard crankshaft journal cannot be precision-fit, it then is ground .002" undersize on all rod journals (.002" will be stamped on crankshaft front counterweight. as shown in Figure 4). INSPECTION and REPLACEMENT 1. With oil pan and oil pump removed, lift off connecting rod cap and bearing. 2. Inspect bearing for evidence of wear or damage (defective bearings should not be installed). Typical bearing failures are shown in Figure 1, preceding. 3. Wipe bearings and crankpin clean of oil. 977R1 MERCRUISER ENGINE - 5C-23 a - Gauging Plastic b- Crankshaft Journal Figure 2. Gauging Plastic on Journal a - Front End of Crankshaft b- Main Journal Mark Location c - Rod Journal Mark Location Figure 4. Undersize Journal Identification NOTE: If bearing is being fitted to out-of-round crankpin, be sure to fit maximum diameter of crankpin. If bearing is fitted to minimum diameter, and crankpin is out-of-round .001 " (0.025mm), interference between bearing and crank- pin will result in rapid bearing failure. a. Place a piece of gauging plastic the full width of crankpin (parallel to crankshaft). (Figure 5) b. Install bearing, connecting rod and cap. Take care that tab in bearings is located correctly in rod and rod cap notches. c. Install bearing cap and torque nuts evenly to specifications. a - Gauging Plastic b- Crankpin c - Connecting Rod Figure 5. Gauging Plastic on Crankpin crankshaft. If within specifications and new bearing is to be installed, measure maximum diameter of crankpin to determine new bearing size required. 5. If within specifications, measure new or used bearing clearances with Plastigage or equivalent, as follows: a - Feeler Gauge b- Crankshaft c - Connecting Rod Figure 7. Measuring Connecting Rod Side Clearance CAUTION: DO NOT turn crankshaft with gauging plastic installed. d. Remove bearing cap and. using scale on gauging plastic envelope, measure gauging plastic width at widest point. (Figure 6) 6. If clearance exceeds specifications, select a new, correct- size bearing and remeasure clearance. 7. Coat bearing surface with oil. install rod cap and torque nuts to specifications. 8. When all connecting rod bearings have been installed, tap each rod lightly (parallel to crankpin) to be sure that they have clearance. 01635 9. Measure all connecting rod side clearances (see specifications) between connecting rod and side of crankpin. (Figure 7) a - Gauging Plastic Compressed b- Gauging Plastic Envelope Figure 6. Measuring Gauging Plastic 5C-24 - MERCRUISER ENGINE 977 R1 PISTON and ROD ASSEMBLY a - Piston Pin Remover c Piston b - Arched Base d - Connecting Rod e - Rod Support Figure 3. Removing Piston Pin a - Mallet b - Rod Guide Tool c - Connecting Rod Figure 1. Removing Piston and Rod Assembly DISASSEMBLY 1. Use Tool Kit (J-24086-100), shown in Figure 2. REMOVAL 1. Remove flywheel housing, coupler and flywheel. 2. Remove cylinder head assembly (see "Index"). 3. Remove oil pan and oil pump. 4. Check connecting rod caps for cylinder number identification. If necessary, mark rod caps and rods. 5. Remove connecting rod caps. Install Rod Guides (J-5239) on connecting rod bolts and push or tap pistons out top of cylinder bores. (Figure 1) 10071 a - Arched Base c - Adjustable Installer b- Rod Support d- Piston Pin Guide e - Piston Pin Remover Figure 2. Tool (J-24086-100) Parts Identification 2. Position connecting rod onto tool rod support with rod support inserted between connecting rod end and piston. Align piston pin with hole located in top of arched base. (Figure 3) 3. Insert pin remover thru hole (located in top of arched base) and into piston pin hole. Press on pin remover to remove piston pin. (Figure 3) CLEANING and INSPECTION Connecting Rods 1. Wash connecting rods in cleaning solvent and dry- with compressed air. 2. Check for twisted or bent rods and inspect for cracks. Replace damaged rods. Pistons 1. Clean varnish from piston skirts and pins with cleaning solvent. DO NOT WIRE BRUSH .ANY PART OF PISTON. 2. Clean ring grooves with groove cleaner (or broken ring). 3. Inspect piston for cracked ring lands, skirts or pin bosses, wavy or worn ring lands, scuffed or damaged skirts and eroded areas at top of piston. Replace pistons which are damaged or have excessive wear. 4. Inspect piston ring grooves for nicks or burrs which might cause rings to hang up. 5. Measure piston skirt (across centerline of piston pin) and check clearance as outlined under "Piston Selection". (See "Index".) Piston Pins 1. Piston and piston pin are matched and not serviced separately. 2. Pin bores and piston pins must be free of varnish or scuffing. Measure piston pin with micrometer and piston pin bore with bore gauge or inside micrometer. If clearance is in excess of wear limit (see specifications), replace piston and pin assembly. MERCRUISER ENGINE - 5D-25 REASSEMBLY 2. Lubricate piston pin, piston pin hole in piston and hole in rod end with a light coat of engine oil. 1. Piston and connecting rod are reassembled with connecting rod bearing tang slots and hole in oil ring groove 3. Position rod onto rod support and piston onto rod end, as positioned as shown in Figure 4. shown in Figure 4. Insert piston pin guide thru bottom piston pin hole and into connecting rod. Place piston pin thru top side of piston. (Figure 5) 4. Adjust adjustable installer to setting specified on chart (which came with tool) for particular piston installation. Lock adjustable installer with jam nut. 5. Insert adjustable installer thru hole (located on top of arched base) and into piston pin hole. Carefully press on adjustable installer until installer bottoms-out on arched base to install piston pin. PISTON RINGS 1. Select rings comparable in size to piston being used. 2. Slip compression ring in cylinder bore where ring will be used. Press ring squarely about 54" (6.4mm) into cylinder bore. 3. Measure space or gap between ends of ring with feeler gauge. (Figure 6) If gap is below specification, remove ring and try another for fit. 4. Clean, inspect and fit piston to cylinder (as previously outlined), if not already completed. a - Feeler Gauge b - Compression Ring Figure 6. Measuring Ring Gap a - Jam Nut b-Adjustable Installer c - Arched Base d - Piston e - Connecting Rod f - Piston Pin g - Rod Support Figure 5. Installing Piston Pin 10073 5C-26 - MERCRUISER ENGINE 977 R1 a • Bearing Tang Slots b- Hole in Oil Ring Groove c - Oil Ring Groove Figure 4. Connecting Rod and Piston Position o. Insert outer surface of top and second compression ring into respective piston ring groove and roll ring entirely around groove (Figure 7) to make sure that ring fit is free. If binding occurs at any point, determine the cause and, if caused by ring groove, remove by dressing with fine cut file. If binding is caused by distorted ring, use new ring. Piston Ring Groove (Top and Second) b- Piston Ring Figure 7. Checking Ring in Groove 6. Refer to Figures 8 and 9 for piston ring installation and complete the following: a. Install oil expander ring in groove with gap located 120° clockwise from No. 1 compression ring gap (starboard side of piston), as shown in Figure 9. b. Hold expander ends butted and install lower steel oil ring rail with gap located approximately 1" (25.4mm) to one side of expander gap. (Figures 8 and 9) c. Install upper steel oil ring rail with gap located approximately 1" to other side of expander gap. (Figures 8 and 9) d. Install second compression ring in piston second groove (Figure 8) with gap located 120° counterclockwise from No. 1 compression ring gap (starboard side of piston), as shown in Figure 9. e. Install top compression ring with gap located at starboard side of piston (starboard or camshaft side of piston has a hole located in oil ring groove). (See Figure 3 in "Piston and Rod Assembly - Reassembly", preceding.) a - Top Compression Ring Gap Location b-Second Compression Ring Gap Location c - Oil Expander Ring Gap Location d- Top and Lower Steel Oil Ring Rail Gap Location e - Centerline f - Starboard or Camshaft Side of Piston with Hole Located in Oil Ring Groove g - 120° Clockwise from No. 1 Compression Ring Gap Location h- 120° Counterclockwise from No. 1 Compression Ring Gap Location i - Approximately 1" Figure 9. Piston Rings Gap Location a - Top Compression Ring c - Top and Lower Steel b-Second Compression Ring Oil Ring Rail d - Oil Expander Ring Figure 8. Piston Ring Identification 977R1 MERCRUISER ENGINE - 5C-27 7. Measure clearances between compression ring and groove. (See "Specifications" Section 8.) If ring cannot be fitted, piston must be replaced. PISTON and ROD ASSEMBLY INSTALLATION NOTE: If connecting rod bearings require replacement, refer to "Connecting Rod Bearings", preceding. Be sure to install new pistons in same cylinders for which they were fitted and used pistons in same cylinders from which they were removed. 1. Clean cylinder bores with hot water and detergent wash or with light honing, as necessary. After cleaning, swab bores several times with light engine oil and clean cloth. 2. Install fitted connecting rod bearings in rods and rod caps. (See "Connecting Rod Bearings", preceding.) Lubricate rod bearings with engine oil. 3. Lightly coat pistons, rings and cylinder walls with light engine oil. 4. With bearing caps removed, install Tool (J-5239) on connecting rod bolts. 5. With ring gaps properly positioned (as previously outlined), install each connecting rod and piston assembly in respective bore (number side of rod facing camshaft). Compress rings with Ring Compressor and strike light blows with hammer handle to install piston into bore. (Figure 10) Hold ring compressor firmly against block until all piston rings have entered cylinder bore. 6. Remove guide tool from rod bolts. 7. Install bearing caps and torque nuts to specifications. (Figure 11) a - Ring Compressor b - Hammer Handle c - Piston Figure 10. Installing Piston and Rod Assembly into Cylinder Bore a - Torque Wrench b - Rod Cap Figure 11. Torquing Rod Cap 977 R1 5C-28 - MERCRUISER ENGINE CYLINDER BLOCK CLEANING and INSPECTION 1. Wash cylinder block thoroughly in cleaning solvent and clean all gasket surfaces. 2. Remove oil gallery plugs and clean all oil passages. NOTE: Remove plugs with a sharp punch or drill and pry out. a - At Right Angle to Centerline of Engine b- Parallel to Center- line of Engine Taper - Difference between "a" Measurement at Top of Cylinder Bore and "a" Measurement at Bottom of Cylinder Bore Out-of-Round - Difference between "a" and "b" c - Centerline of Engine Figure 1. Cylinder Measurement 3. Clean and inspect water passages in cylinder block. 4. Inspect cylinder block for cracks in cylinder walls, water jacket valve lifter bores and main bearing webs. 5. Measure the cylinder walls for taper, out-of-round or excessive ridge at top of ring travel (Figure 1) with dial indicator. (Figure 2) Set gauge so that thrust pin must be forced in about (6.4mm) to enter gauge in cylinder bore. Center gauge in cylinder and turn dial to "0". Carefully work gauge up-and-down cylinder to determine taper and turn gauge to different points around cylinder wall to determine out-of-round condition. If cylinders exceed specifications, honing and/or boring are necessary. 01643 a - Dial Indicator b- Cylinder Bore Figure 2. Measuring Typical Cylinder Bore REPAIRS Cylinder Conditioning Condition of engine at time of repair is important. If inspection indicates that cylinder block is acceptable, except for out-of-round or tapered cylinders, condition the block bv honing or boring. If cylinders have less than .005" (0.127mm) taper or wear, condition them with a hone and fit with high-limit, standard size piston. A cylinder bore of less then .005" wear or taper may not clean up entirely when fitted to a high limit piston. If such is the case, clean up bore entirely by reboring for an oversize piston. If more than .005" taper or wear, bore and hone to smallest oversize that permits complete resurfacing of all cylinders. When pistons are fitted (honing not necessary), clean (scrub) cylinder bores with detergent and hot water. After cleaning, swab cylinder bores several times with light engine oil on clean cloth, then wipe with clean, dry cloth. Cylinder Boring 1. Before using any type boring bar, file off top of cylinder block to remove dirt or burrs. This will guard against a tilted boring bar and assures that rebored cylinder wall is at right angles to crankshaft. 2. Measure piston to be fitted with a micrometer at center of piston skirt and at right angles to piston pin. Bore cylinder to same diameter as piston and hone cylinder to specifications (Section 8) and as outlined under "Cylinder Honing" and "Piston Selection", following. 3. Carefully follow instructions furnished by manufacturer of equipment being used. Cylinder Honing 1. Follow hone manufacturer's recommendations for use of hone and cleaning and lubrication during honing. 2. Occasionally, during honing operation, thoroughly clean cylinder bore and check piston for correct fit in cylinder. 3. When finish-honing a cylinder bore to fit a piston, move hone up-and-down to obtain very fine uniform surface finish marks in a cross-hatch pattern of approximately 30° to cylinder bore. Finish marks should be clean but not sharp and free from imbedded particles and torn or folded metal. CAUTION: Handle pistons with care and DO NOT attempt to force them thru cylinder until cylinder has been honed to correct size, as this type piston can be distorted thru careless handling. 4. Permanently mark piston for cylinder to which it has been fitted and proceed to hone cylinders and fit remaining pistons. 5. Thoroughly clean cylinder bores with hot water and detergent. Scrub well with a stiff bristle brush and rinse thoroughly with hot water. Be absolutely certain that no abrasive material is allowed to remain in cylinder bores, or it will rapidly wear new rings and cylinder bores in 976 MERCRUISER ENGINE - 5D-29 addition to bearings lubricated by contaminated oil. Swab bores several times with light engine oil on a clean cloth, then wipe with a clean, dry cloth. DO NOT clean cylinder with kerosene or gasoline. Clean remainder of cylinder block to remove excess material spread during honing operation. PISTON SELECTION When a production standard piston cannot be precision-fit, cylinder bore is enlarged .005" (0.127mm) and oversize pistons are installed in all cylinders (.005" is stamped on cylinder block in area shown in Figure 3). 1. Check USED piston to cylinder bore clearance as follows: a. Measure "Cylinder Bore Diameter" with a telescope gauge 2Vz" (63.5mm) from top of cylinder bore. b. Measure "Piston Diameter" (at skirt across centerline of piston pin). c. Subtract piston diameter from cylinder bore diameter to determine "Piston to Bore Clearance". d. Determine if piston to bore clearance is in acceptable range. (See "Specifications" in Section 8.) 2. If used piston is not acceptable, check oversize pistons available. Refer to Parts Manual. 3. If cylinder bore must be reconditioned, measure new a - Identification Mark Location b-Serial Plate Figure 3. Oversize Cylinder Bore Identification Mark Location piston diameter (across centerline of piston pin), then hone cylinder bore to correct clearance. 4. Mark piston to identify cylinder for which it was fitted. 5C-30 - MERCRUISER ENGINE 977 R1 DRIVE SYSTEMS MERCRUISER Section 6 08920 TABLE of CONTENTS Page MerCruiserlDriveUnit 6A-1 General Service Recommendations 6A-1 Gear Housing Removal 6A-3 Gear Housing Disassembly 6A-4 Gear Housing Reassembly 6A-8 Gear Housing Installation 6A-13 Drive Shaft Housing Removal 6A-15 Drive Shaft Housing Disassembly 6A-15 Drive Shaft Housing Reassembly 6A-18 Drive Shaft Housing Installation 6A-21 Hydraulic Power Trim Transom Plate Assembly without Side-Mounted Rotary Switch 6A-22 Gimbal Housing Ball Bearing 6A-22 Tilt Stop Switch Assembly 6A-23 Exhaust Elbow and Shutter Replacement.. 6A-25 Gimbal Housing Disassembly 6A-25 Gimbal Housing Reassembly 6A-30 Hydraulic Power Trim Transom Plate Assembly with Side-Mounted Rotary Switch 6A-34 Gimbal Housing Ball Bearing 6A-35 Exhaust Elbow and Shutter Replacement... 6A-36 Trim Limit Switch and Trim Position Sender 6A-37 OuterTransom Assembly Disassembly 6A-38 OuterTransom Assembly Reassembly 6A-42 Manual Trim Transom Plate Assembly with Side-Mounted Rotary Switch 6A-46 MerCruiserH-TR Drive Unit 6B-1 Service Recommendations 6B-1 GearHousing Assembly 6B-2 Gear Housing Removal 6B-3 Gear Housing Disassembly - Right Hand Rotation 6B-3 Gear Housing Reassembly - Right Hand Rotation 6B-8 GearHousing Installation 6B-12 Drive Shaft Housing Assembly 6B-13 Drive Shaft Housing Removal 6B-14 Drive Shaft Housing Disassembly 6B-14 Drive Shaft Housing Reassembly 6B-19 Page Drive Shaft Housing Installation 6B-23 Gimbal Housing Disassembly 6B-23 Gimbal Housing Reassembly 6B-26 Trim Switch and Trim Sender Installation ... ..........6B-27 Trim Limit Readjustment 6B-27 Trim IndicatorSenderAdjustment 6B-27 MerCruiserH-TRS Drive Unit 6C-1 General Service Recommendations 6C-1 GearHousing Assembly 6C-2 Gear Housing Reassembly (Right Hand Rotation) 6C-8 GearHousing Installation 6C-12 Drive Shaft Housing 6C-12 Gimbal Housing 6C-12 Direct Drive Transmission 6D-1 Stern Drive Direct Drive Transmission Series 71 and 72 6D-1 Description 6D-1 Precautions 6D-1 Lubrication Recommendations 6D-1 Troubleshooting 6D-2 Removal 6D-4 Disassembly 6D-4 Cleaning and Inspection 6D-10 Reassembly 6D-10 Shift Cable Adjustment 6D-17 Tools 6D-19 MerCruiserH-TR and H-TRS Transmission 6E-1 Transmission Model A 6E-1 Description 6E-1 Precautions 6E-1 Tools 6E-1 Lubrication Recommendations 6E-1 Troubleshooting 6E-2 Transmission 6E-2 Removal 6E-2 Disassembly and Repair 6E-3 Transmission Reassembly 6E-13 Installation 6E-15 SECTION 6 - DRIVE SYSTEMS PART A - MERCRUISER X-DRIVE UNIT A BRUNSWICK COMPANY INDEX Page General Service Recommendations 6A-1 Gear Housing Removal 6A-3 Gear Housing Disassembly 6A-4 Water Pump 6A-4 Bearing Carrier, Reverse Gear, Carrier Retainer and Tab Washer 6A-4 Drive Shaft and Pinion Gear 6A-5 Propeller Shaft and Forward Gear Assembly 6A-6 Shift Shaft Assembly 6A-7 Roller Bearing (Drive Shaft) and Bearing Cups (Drive Shaft and Forward Gear) 6A-7 GearHousing 6A-7 Gear Housing Reassembly 6A-8 Roller Bearing (Drive Shaft) and Bearing Cups (Drive Shaft and Forward Gear) 6A-8 Shift Shaft Assembly - 6A-8 Propeller Shaft and Forward Gear Assembly 6A-9 Drive Shaft and Pinion Gear 6A-9 Bearing Carrier, Reverse Gear, Carrier Retainer and Tab Washer 6A-10 Water Pump 6A-12 Gear Housing Installation 6A-13 Drive Shaft Housing Removal 6A-15 Drive Shaft Housing Disassembly 6A-15 Top Cover and Water Pocket Cover 6A-15 Universal Joint, Drive Gear and Bearing Assembly. 6A-15 Upper Drive Shaft and Driven Gear Assembly ... . 6A-16 Bearing Cup (Driven Gear) and Oil Seals 6A-17 Intermediate Shift Shaft 6A-17 Drive Shaft Housing 6A-17 Drive Shaft Housing Reassembly 6A-18 Bearing Cup (Driven Gear) and Lower Oil Seal . . . 6A-18 Upper Drive Shaft and Driven Gear Assembly ... . 6A-18 Top Cover and Top Oil Seal 6A-18 Universal Joint, Drive Gear and Bearing Assembly. . .......6A-19 Intermediate Shift Shaft 6A-21 Water Pocket CoverDrive Shaft Housing InstallationHydraulic Power Trim Transom Plate Assembly without Side-Mounted Rotary SwitchGimbal Housing Ball BearingTilt Stop Switch AssemblyExhaust Elbow and Shutter ReplacementGimbal Housing Disassembly Bell Housing Gimbal Ring Gimbal Housing Gimbal Housing ReassemblyGimbal HousingGimbal RingBell Housing Hydraulic Power Trim Transom Plate Assembly with Side-Mounted Rotary SwitchGimbal Housing Ball BearingExhaust Elbow and Shutter ReplacementTrim Limit Switch and Trim Position SenderOuter Transom Ass'y Disassembly Shift Cable Bell Housing Gimbal Ring Gimbal Housing Outer Transom Ass'y ReassemblyGimbal HousingGimbal RingBell HousingShift Cable Manual Trim Transom Plate Assembly with Side-Mounted Rotary SwitchTilt (Cutout) Rotary SwitchRelay SolenoidReverse Lock Assembly Pag' 6A-21 6A-21 6A-22 6A-22 6A-23 6A-25 6A-25 6A-26 6A-27 6A-29 6A-30 6A-30 6A-30 6A-32 6A-34 6A-35 6A-36 6A-37 6A-38 6A-38 6A-39 6A-40 6A-41 6A-42 6A-42 6A-42 6A-43 6A-45 6A-46 6A-46 6A-46 6A-46 GENERAL SERVICE RECOMMENDATIONS Instructions are printed in the sequence which will be followed to assure best results when removing or replacing components. Follow "Disassembly" and "Reassembly" procedures as written, however, if complete disassembly is not necessary, start reassembly at point that disassembly was stopped (use "Index"). In order to assure correct and durable operation after assembly, it is important that all adjustments and torque value specifications be maintained to the highest degree of accuracy. Use special service tools, where specified, and use common tools of proper fit when removing and replacing parts. When holding housings or parts in a vise - or by other means -use blocks of wood and/or brass shields to prevent marring parts' surfaces. Pressed-on parts (bearings, gears, etc) require adapting appropriate mandrels and supports for the press used. Do not apply force on the bearing cages, mating surfaces or edges which will mar or fail if force is applied. When pressing bearings or bearing cups into housings or onto shafts and gears, apply thin coat of Multipurpose Lubricant (C-92-63250) to contact surfaces. To prevent corrosive action during reassembly, apply Perfect Seal (C-92-34227) to external parts of bearing carrier, bearing carrier retainer and housing mating surfaces. DO NOT allow sealer to contact "0 " rings or enter bearings and gears. To ease installation of drive unit components, apply Multipurpose Lubricant to lip of all oil seals and "0 " rings. To prevent oil leakage, apply Loctite Type "A " (C-92-32609) on outside diameter of all metal case oil seals. When using Loctite on oil seals or threads, surfaces must be clean and dry. Refer to Section 8, "Specifications", for all torque specifications. Keep a record of shim amounts and location. Be sure to follow shimming instructions closely. Gears must be mounted to correct feeler gauge reading and correct gear backlash to avoid noisy performance and premature failure. Bearing preload must be within specifications, or bearing failure may result. Threaded parts are right hand (RH), unless otherwise indicated. Drive unit should be completely disassembled, inspected and cleaned, if either gear housing or drive shaft housing has indicated a failure. 576R1 MERCRUISER DRIVE SYSTEMS -6A-1 1 - "O" Ring 2 - Drive Shaft 3 - Centrifugal Slinger 4 - Oil Seal 5 - Insert 6 - Impeller 7 - Guide 8 - Seal 9 - Water Pump Body 10 - Plate and Gaskets 11 - Water Pump Base 12 - Oil Seals 13 - Bearing 14 - Shims 15 - Allen Screw 16 - Trim Tab 17 - Gear Housing 18 - Metal and Rubber Washer 37 - Bearing Carrier 38 - Bearing 39 - Tab Washer 40 - Retainer 41 - Thrust Hub 42 - Propeller Shaft 43 - Splined Washer 44 - Tab Washer 45 - Nut 19 - Shift Shaft Bushing 20 - Washer 21 - Clip 22 - Shift Shaft 23 - Drive Shaft Bearing 24 - Pinion Gear 25 - Forward Gear 26 - Bearing 27 - Shift Crank 28 - Spool 29 - Adjusting Sleeve 30 • Shims 31 - Sliding Clutch 32 - Retainer Spring 33 - Reverse Gear 34 - Shims 35 - Thrust Ring 36 - Bearing Figure A. Gear Housing Parts Identification 6A-2 - MERCRUISER DRIVE SYSTEMS GEAR HOUSING REMOVAL 1. Drain lubricant from drive unit by removing drain plug CAUTION: If metal particles or water are present in from lower end of gear housing on left side (Figure 1) and drive unit lubricant, both gear housing and drive shaft vent plug on drive shaft housing. (Figure 2) housing must be disassembled, cleaned in solvent and closely inspected. Replace all oil seals and any unserviceable parts. 2. Place a block of wood between propeller and anti- cavitation plate to prevent propeller from turning while removing propeller nut. 3. Remove propeller by bending tabs on tab washer and removing propeller nut (right hand thread), tab washer, splined washer, propeller and thrust hub assembly. (Figure 3) Trim Tab Fi Drain Hole 03112 Thrust Hub' Quicksilver Propeller Figure 1. Drain Plug in Gear Housing Spline Washer Tab bb Washer Propeller Nut 08058 Figure 3. Propeller and Gear Housing Removal 4. Remove trim tab under trailing edge of anti-cavitation plate by removing plastic plug from rear top of drive shaft housing and turning alien head screw out of trim tab. (Figure 3) 5. Remove gear housing alien head screw from inside trim tab cavity. 6. Remove five 5/8 " hexagon head locknuts which hold gear housing assembly to drive shaft housing. (Figure 3) 7. Separate gear housing from drive shaft housing. NOTE: If gear housing is to be disassembled, check backlash between gears at this time (for future reference). Refer to "Shimming (Forward and Reverse Gears)" under Figure 2. Vent Plug in Drive Shaft Housing "Gear Housing Reassembly" (see "Index"). MERCRUISER DRIVE SYSTEMS -6A-3 GEAR HOUSING DISASSEMBLY WATER PUMP REMOVAL 1. Set gear housing in vise in upright position with skeg held between 2 blocks of wood. 2. Remove "0 " ring from upper end of drive shaft. 3. Remove rubber centrifugal slinger from drive shaft. 4. Remove one screw and 3 nuts and washers which hold water pump body in place. 5. Use 2 screwdrivers (in slots provided) and pry water pump body from pump base. 6. Remove water pump impeller and impeller drive pin. 7. Remove face plate and 2 gaskets. 8. Pry pump base loose and remove base from drive shaft. Take care not to damage gear housing mating surface with pry tool. 9. Remove pump base to gear housing gasket. CLEANING and INSPECTION 1. Clean metal parts in solvent and dry with compressed air. DO NOT allow solvent to remain on oil seals, or seals will become unserviceable. NOTE: Late drive units do not have oil seal in water pump body. 2. Inspect oil seals in water pump body and pump base for wear, tears, roughness and proper spring positioning. If there is any doubt about oil seal serviceability, replace oil seals. 3. Check surface of drive shaft where oil seal lips contact shaft. Any groove in drive shaft in this area requires oil seals and shaft replacement. 4. Water pump impeller is checked for wear on end of impeller blades and on top and bottom edge of blades. Check bonding between hub and impeller. Blades that have taken a "set" (stay in curved position) should also be replaced. 5. Inspect water pump face plate and insert for roughness and grooves. Replace parts if a defect is found. 6. Check "0 " ring for cuts, nicks, hardness and cracks. If "0 " ring serviceability is doubtful, replace "0 " ring. 7. .Always use NEW water pump gaskets. DISASSEMBLY 1. Remove water tube guide and seal from water pump body assembly. 2. Remove oil seals from water pump housings. NOTE: Late drive units do not have oil seal in water pump body. 3. Place pump body on top of open vise and drive insert out of body. 4. Remove "0 " ring from pump base. BEARING CARRIER, REVERSE GEAR, CARRIER RETAINER and TAB WASHER REMOVAL 1. Straighten tab on bearing carrier retainer tab washer. 2. Loosen bearing carrier retainer by turning counterclockwise with Bearing Carrier Retainer Wrench (C-91-61069). (Figure 1) Remove retainer and tab washer. 3. Use Slide Hammer (C-91-34569A1) with Jaws (C-91-34570) for removing bearing carrier assembly. (Figure 2) The thrust hub may be used to keep puller jaws in place. (Figure 2) Do not lose carrier retaining key. 4. Remove bearing carrier to gear housing shims. 1. Clean parts in solvent and dry with compressed air. DO NOT allow solvent to remain on oil seals, or seals will become unserviceable. 2. Inspect oil seals for wear, tears, roughness and proper spring position. If oil seal serviceability is doubtful, replace oil seals. Inspect surface of propeller shaft where oil seal 06914 lips contact shaft. Any groove in propeller shaft in this Figure 1. Removing Bearing Carrier Retainer area requires oil seals and shaft replacement. Figure 2. Removing Bearing Carrier CLEANING and INSPECTION 6A-4 - MERCRUISER DRIVE SYSTEMS 3. Apply a very light coat of oil to reverse gear ball bearing. Rotate bearing and check for rough spots. Grasp reverse gear in one hand and bearing carrier in other. Pull and push to check for side wear. Any excessive movement is cause for replacement. 4. Check roller bearing for serviceability by inspecting bearing contact surface on propeller shaft. Pitting, grooves, scoring, discoloration from overheating, uneven wear and embedded foreign metal particles are reason for bearing and propeller shaft replacement. Inspect reverse gear for pitting, chipped or broken teeth and excessive or uneven wear. Check reverse gear clutch engaging surface. Surface must not be chipped or rounded- off. 6. Inspect "0 " ring for cuts, nicks, hardness and cracks. If "0 " ring serviceability is doubtful, replace "0 " ring. 03472 Check threaded retainer for cracks and broken or corroded Figure 3. Removing Ball Bearing from Reverse Gear threads. 5. Pull roller bearing from carrier, using Drive Head 8. Replace tab washer. DO NOT re-use. (C-91-36569) with Bearing Removal and Installation Kit 9. Replace all damaged shims with new shim of same (C-91-31229A4). (Figure 4) Drive Rod (C-91-37323), used thickness. in conjunction with arbor press and Drive Head (C-91-36569), also may be used. DISASSEMBLY IMPORTANT: Clamp only on reinforcing fin of carrier, or carrier may be damaged. 1. Clamp bearing carrier assembly in a vise and use Slide Hammer (C-91-34569A1) to pull reverse gear. 2. Remove "0 " ring. 3. Remove ball bearing from reverse gear with Universal Puller Plate (C-91-37241) and arbor press. (Figure 3) NOTE: If ball bearing remained in bearing carrier, use Slide Hammer to remove bearing. 4. Oil seals can be removed from carrier by prying them out or driving or pulling them out, along with roller bearing. DRIVE SHAFT and PINION GEAR REMOVAL 1. Install Pinion Nut Adaptor (C-91-61067A1) over propeller shaft and onto pinion gear nut. Turn drive shaft counterclockwise with Drive Shaft Wrench Adaptor (C-91-56775) Drive Shaft \ to remove nut. (Figure 5) Wrench (C-91-56775) NOTE: If drive shaft is broken, use small adaptor (part of Pinion Nut Adaptor [C-91-61067A1 ]) on propeller shaft and turn propeller shaft to loosen pinion gear nut. 2. To remove drive shaft from pinion gear splines, it may be necessary to clamp shaft in a vise (using brass jaws) as close to gear housing as possible. Use block of wood to protect gear housing and drive gear from end of drive shaft as shown in Figure 6. Figure 5. Loosening Pinion Gear Nut 08490 MERCRUISER DRIVE SYSTEMS -6A-5 Figure 6. Removing Drive Shaft Figure 6. Removing Drive Shaft CLEANING and INSPECTION 1. Clean in solvent and dry with compressed air. 2. Inspect pinion gear for pitting, chipped or broken teet* and excessive or uneven wear. 3. Inspect area of drive shaft where roller bearing rides. Pitting, grooves, scoring, uneven wear, discoloration from overheating and embedded foreign metal particles are causes for replacement of drive shaft and roller bearing. 4. Check drive shaft tapered roller bearing by inspecting bearing cup. Replace bearing and bearing cup if cup is pitted, grooved, scored, worn uneven, discolored from overheating of if foreign metal particles are embedded in cup. 5. Inspect drive shaft splines (both ends) for wear. 6. If propeller shaft is bent, check drive shaft for straightness. DISASSEMBLY Press tapered roller bearing from drive shaft with Universal Puller Plate (C-91-37241) and arbor press. PROPELLER SHAFT and FORWARD GEAR ASSEMBLY REMOVAL Tilt propeller end of propeller shaft toward oil fill hole side of gear housing, disengaging spool from shift crank in gear housing, then lift assembly from housing. CLEANING and INSPECTION 1. Clean parts in solvent and dry with compressed air. 2. Inspect forward gear for pitting, chipped or broken teeth and excessive or uneven wear. Check forward gear clutch engaging surface. Surface must not be chipped or rounded off. 3. Check sliding clutch engaging surface for chipped or rounded-off condition. Damaged clutch engaging surface indicates incorrect shift cable adjustment, worn parts or poor shifting habits of operator (slow shifting of control shift lever and/or engine RPM too high while shifting). 4. Inspect forward gear tapered roller bearing by inspecting bearing cups. Replace bearing and bearing cup if cup is pitted, grooved, scored, worn uneven, discolored from overheating or if foreign metal particles are embedded in cup. 5. Check propeller shaft for straightness: a. Place propeller shaft on balance wheels and spin shaft. Observe shaft for wobble on propeller end of shaft. Replace if bent. b. Place propeller shaft on "V " blocks. Rotate shaft. If propeller end of shaft wobbles, replace shaft. c. Place shaft between centers in lathe. Place dial indicator in area of needle bearing. If total indicator variation is greater than .005" (.13mm) as shaft isrevolved, replace shaft. 6. dean all corrosion (with wire brush) from propeller shaftsplines. If splines are partially corroded away, replace shaft. 7. To inspect forward gear roller bearing (located on insidediameter of gear), gear must be removed from propeller shaft assembly. Refer to "Propeller Shaft and Forward Gear Disassembly", following. Inspect area of propeller 2. 3. 4. 5. shaft where roller bearing rides. Pitting, grooves, scoring, uneven wear, discoloration from overheating and embedded foreign metal particles are all reasons for replacement of bearing and shaft. 8. Check shift spool for wear. DISASSEMBLY 1. Remove cotter pin from adjusting sleeve and remov, sleeve. (Figure 7) Figure 7. Propeller Shaft Components Spool assembly and forward gear assembly now can be removed from shaft. Remove retainer washers and spring from spool. Press tapered roller bearing from gear with Puller Plate (C-91-37241), proper mandrel and arbor press. Forward gear roller bearing (located on inside diameter of gear) must be broken for removal. Split bearing case with i chisel, then remove bearing. Remove sliding clutch cross pin retaining spring and push cross pin out with a punch. Sliding clutch and clutch actuating shaft now can be removed from propeller shaft. (Figure 7) 6A-6 - MERCRUISER DRIVE SYSTEMS SHIFT SHAFT ASSEMBLY REMOVAL 1. Remove metal washer and rubber washer from shift shaft. 2. Use Shift Shaft Bushing Tool (C-91-31107) to remove shift shaft bushing. (Figure 8) 3. Shift shaft now can be pulled out of gear housing. 4. Shift crank now is loose in gear housing and can be removed from its locating pin. CLEANING and INSPECTION 1. dean parts in solvent and dry with compressed air. DO NOT allow solvent to remain on shift shaft bushing oil seal and "0 " ring, or seal and "0 " ring will become unserviceable. 2. Inspect shift shaft splines (where it engages upper shift shaft) for wear and corrosion. 3. Inspect shift shaft bushing for corrosion damage. 4. Inspect shift shaft bushing oil seal for wear, tears, roughness and proper spring position. Check "0 " ring for cuts, nicks, harness and cracks. If "0 " ring or oil seal serviceability is doubtful, replace them. 5. Replace shift crank if worn. DISASSEMBLY 1. Remove oil seal from bushing by driving seal out through top of bushing. ROLLER BEARING (DRIVE SHAFT) and BEARING CUPS (DRIVE SHAFT and FORWARD GEAR) Figure 8. Removing Shift Shaft Bushing 2. Remove "0 " ring from bushing. 3. Remove clip from shift shaft. REMOVAL NOTE: Do not remove drive shaft roller bearing, unless replacement is necessary. 1. Remove drive shaft roller bearing from gear housing with Driver Head (C-91-36569) and Driver Rod (C-91-37323). (Figure 9) 2. Remove drive shaft and forward gear tapered roller bearing cups with Slide Hammer (C-91-34569A1), then remove shims from under cups. CLEANING and INSPECTION 1. Inspect area of drive shaft where roller bearing rides. Pitting, grooves, scoring, uneven wear, discoloration from overheating and embedded foreign metal particles are causes for replacement of bearing and drive shaft. 2. Check drive shaft and forward gear tapered roller bearing cups by inspecting bearing cups. Replace bearings and bearing cups if cups are pitted, grooved, scored, wom uneven, discolored from overheating or have foreign metal particles embedded in the cup. 3. Replace all damaged shims with new shim of same thickness. GEAR HOUSING CLEANING and INSPECTION 3. Check for loose fitting bearing cups and roller bearings. 4. Inspect bearing carrier retainer threads in gear housing for 1. dean assembly in solvent and dry with compressed air. corrosion or stripped threads. 2. Check gear housing carefully for impact damage. 5. Inspect painted surface of gear housing. MERCRUISER DRIVE SYSTEMS - 6A-7 GEAR HOUSING REASSEMBLY ROLLER BEARING (DRIVE SHAFT) and BEARING CUPS (DRIVE SHAFT and FORWARD GEAR) INSTALLATION CAUTION: If drive shaft roller bearing failure has occurred, and original bearing case has turned in gear housing, gear housing must be replaced. Loose fitting roller bearings will move out of position and cause repeated failures. 1. Apply thin coat of Multipurpose. Lubricant (C-92-63250) to drive shaft roller bearing bore in gear housing. Install drive shaft roller bearing into gear housing with numbered end of bearing case facing up-and-away from pinion gear toward cavitation plate. 2. Install bearing with the following tools from Bearing Removal and Installation Kit (C-91-31229A4): Puller Rod with Nut (C-91-31229), Pilot (G91-36571), Plate (C-91-29310) and Puller Head (C-91-38628), as shown in Figure 2. Forward Bearing Cup Installation Figure 1. Install bearing until bearing bottoms on gear housing shoulder. 3. Place forward gear bearing cup shims in gear housing. Use same thickness of shims that were removed in disassembly. 4. Place bearing cup in gear housing and install cup with Driver Cup (C-91-36577), Driver Rod (C-91-37323) and Adaptor (C-91-37263), as shown in Figure 2. 5. Install drive shaft tapered roller bearing cup and shims in same manner as forward gear bearing cup. Use Driver Cup (C-91-34379), Driver Rod (C-91-37323) and Adaptor (C-91-37263). SHIFT SHAFT ASSEMBLY REASSEMBLY 2. Install shift shaft (with retaining clip) into gear housing, coupling it to shift actuating crank, then place retaining 1. Install oil seal in shift shaft bushing. washer over shift shaft on top side of retaining clip. 2. Install "0'" ring on shift shaft bushing. 3. Lubricate lip of oil seal and "0 " ring with Multipurpose 3. Place clip in groove on shift shaft. Lubricant (C-92-63250) to ease installation and install shift shaft bushing. Tighten bushing securely with Tool INSTALLATION (C-91-31107). 4. Place rubber washer and upper metal washer on shift shaft. 1. Set shift crank on locating pin. with "throw" side of crank Use Multipurpose Lubricant to hold metal washer in place facing oil fill hole side of gear housing. until gear housing installation is made. 03484 03325 Figure 1. Installing Drive Shaft Bearing 6A-8 - MERCRUISER DRIVE SYSTEMS PROPELLER SHAFT and FORWARD GEAR ASSEMBLY REASSEMBLY 1. Install forward gear roller bearing (located on inside diameter of gear) with a proper adaptor. 2. Press forward gear tapered roller bearing onto forward gear, using suitable adaptor to apply pressing force on center race of bearing. Seat bearing against shoulder of gear. 3. Place first washer, spring and second washer into shift actuating spool, then thread on retainer and tighten. 4. Place sliding clutch on propeller shaft with grooved end of clutch toward reverse gear end of shaft. (Figure 3) Position Gear » Groove 03387 Figure 3. Assembling Propeller Shaft Components splines in clutch with shaft so that cross pin holes in clutch and shaft are aligned. 5. Install forward gear and bearing assembly with gear facing sliding clutch. 6. Insert clutch actuating shaft into hole (located in end of propeller shaft). .Align hole in actuating shaft to match cross pin holes in sliding clutch and propeller shaft. 7. Insert cross pin through sliding clutch, propeller shaft and actuating shaft. 8. Install cross pin retainer spring around sliding clutch within clutch retainer groove. CAUTION: Do not over-stretch spring when installing. 9. Slide spool assembly over clutch actuating shaft and thread adjusting sleeve onto shaft until sleeve touches washer and slight resistance is felt. Back off sleeve until next cotter pin slot is aligned with hole in shaft. Install cotter pin. Spool MUST spin freely on shaft. INSTALLATION Install propeller shaft assembly into gear housing by tilting propeller end of propeller shaft toward oil fill hole side of gear housing. This will allow engagement of shift actuating shaft spool with shift crank. Straighten propeller shaft and operate shift shaft. Sliding clutch ONLY should move when shift shaft is turned, if installation was properly made. DRIVE SHAFT and PINION GEAR REASSEMBLY Press tapered roller bearing on drive shaft with suitable adaptor to apply pressing force on center race of bearing. Seat bearing against shoulder of shaft. INSTALLATION 1. Place pinion gear into position in gear housing and install drive shaft through pinion gear. 2. Place a drop of Loctite Type "A " (C-92-32609) on pinion gear nut threads and install nut. Torque nut to specifications with Drive Shaft Wrench (C-91-56775) to aid in turning shaft and Pinion Nut Adaptor (C-91-61067A1) to hold nut from turning. (Figure 4) Figure 4. Torquing Pinion Gear Nut I Drive Shaft Wrench (C-91-56775) 08491 t Torque Wrench MERCRUISER DRIVE SYSTEMS -6A-9 SHIMMING (PINION GEAR) a. Turn drive shaft to position bearing rollers. Use Pinion Gear Shimming Tool (C-91-56048) and check for .025" (.635mm) clearance between gear and tool while applying inward pressure on drive shaft to seat its roller bearing. (Figure 5) b. If clearance is not correct, remove pinion gear, drive shaft and bearing cup. If clearance is over .025", remove shims from under bearing cup; if under .025", add shims under bearing cup, then repeat steps No. 1 and 2, immediately preceding. c. If clearance is correct, continue gear housing reassembly. NOTE: Pinion Gear Shimming Tool accurately positions pinion gear in gear housing and eliminates misalignment of gear mesh (not gear backlash) between pinion gear and forward and reverse gears. Shimming Tool may be used on earlier MerCruiser 120-140-160-165 gear housings which Figure 5. Shimming Procedure have late pinion gear (B-43-55812) installed. BEARING CARRIER, REVERSE GEAR, CARRIER RETAINER and TAB WASHER REASSEMBLY 1. Press roller bearing into bearing carrier (Figure 6) with Bearing Driver (C-91-37263) and Driver Rod (C-91-37323). 2. Install oil seals with Loctite Type "A " (C-92-32609) on outside diameter. Use deep shouldered end of Oil Seal Driver (C-91-31108) to install first oil seal with lip in. (Figure 7) Use opposite end of tool to seat second seal with lip outward. (Figure 8) 3. Fill area between oil seals with Multipurpose Lubricant (C-92-63250). 4. Install reverse gear ball bearing and thrust washer onto reverse gear with beveled side of thrust washer toward Tool (C-91-37263) reverse gear. Use proper mandrel on ball bearing so that pressing force will be applied to inner race of bearing. Roller 5. Press reverse gear and ball bearing assembly into bearing carrier. 6. Install "0 " ring between carrier and thrust washer. INSTALLATION 1. Lubricate carrier "0 " ring with Multipurpose Lubricant (C-92-63250). 2. Install shims in gear housing. IMPORTANT: On final installation of bearing carrier (after forward and reverse gear backlash has been corrected), apply Perfect Seal (C-92-34227) liberally to outer Figure 6. Installing Roller Bearing in Carrier diameters of carrier which contact gear housing. Surfaces 6A-10 - MERCRUISER DRIVE SYSTEMS 03481 Figure 8. Installing Second Oil Seal in Carrier |Figure 7. Installing First Oil Seal in Carrier 08526 Bearing must be clean and oil-free. DO NOT allow sealer to enter ball bearing or reverse gear. Also apply sealer to threads liberally in gear housing before installing retainer. 3. Place bearing carrier assembly into gear housing and push down to seat carrier on shims. It may be necessary to turn drive shaft to align teeth of pinion and reverse gears. 4. Place alignment key in bearing carrier to gear housing kevway. 5. Install bearing carrier retainer tab washer, aligning tab washer "V " tab with "V " notch on bearing carrier. NOTE: Refer to "IMPORTANT", following Step 2, immediately preceding. 6. Thread bearing carrier retainer into gear housing and torque to specifications in clockwise direction with Bearing Carrier Retainer Wrench (C-91-61069). NOTE: DO NOT secure carrier retainer with tab washer until forward and reverse gear backlash has been checked and corrected. SHIMMING (FORWARD AND REVERSE GEAR BACKLASH) Forward Gear a. Turn drive shaft clockwise several turns to align rollers in bearings. Fasten dial indicator to gear housing and Backlash Indicator Rod (C-91-53459) to drive shaft. (Figure 9) b. Shift gear housing into full forward. Turn drive shaft clockwise to ensure full engagement of sliding clutch. c. Watch shift shaft movement. Slowly turn propeller shaft clockwise until shift shaft movement stops. Apply pressure on shift shaft toward forward gear. This will friction-lock sliding clutch and forward gear as one unit. d. Position dial indicator pointer to line marked "I " on backlash indicator rod. Hold inward pressure on drive shaft. Lightly turn shaft and pinion gear assembly back-and-forth. DO NOT allow propeller shaft to turn. Dial indicator registers amount of backlash which must be .010" to .012" (.25mm to .30mm). (Figure 9) NOTE: Both forward and reverse gear backlash should be checked at one time so that changing of shims in either gear may be completed in one disassembly procedure. e. If backlash is less than required, remove shims from forward gear bearing race. If backlash is more than required, add shims to forward gear bearing race. Reverse Gear a. Turn drive shaft clockwise several turns to align rollers in bearings. Fasten dial indicator to gear housing and Backlash Indicator Rod (C-91-53459) to drive shaft. (Figure 9) b. Shift gear housing into full reverse. Turn drive shaft clockwise to ensure full engagement of sliding clutch. c. Watch shift shaft movement. Slowly turn propeller shaft counterclockwise until shift shaft movement stops. Apply pressure on shift shaft toward reverse gear. This will friction-lock sliding clutch and reverse gear as one unit. d. Position dial indicator pointer to line marked "I " on backlash indicator rod. Hold inward pressure on drive shaft. Lightly turn drive shaft and pinion gear assembly back-and-forth. DO NOT allow propeller shaft to turn. Dial indicator registers amount of backlash which must be .020" to .025" (,51mm to .64mm). (Figure 9) e. If backlash is less than required, add shims between reverse gear thrust washer and gear housing. If backlash is more than required, remove shims. 7. If forward and reverse gear backlash have been checked and shimming has been corrected, repeat steps No. l-thru-6, immediately preceding. 8. Bend one of the tabs on locking tab washer into one of the slots provided on bearing carrier retainer. MERCRUISER DRIVE SYSTEMS - 6A-11 WATER PUMP REASSEMBLY 1. Install water pump base smaller oil seal with hp of seal toward impeller side of base. 2. Install larger oil seal with lip of seal toward gear housing. 3. Install "0 " ring on water pump base. 4. Press or drive oil seal in pump body with lip facing upward. NOTE: Late drive units do not have oil seal in water pump body. 5. Coat water pump housing insert (outside diameter) with Perfect Seal (C-92-34227). Install insert into pump body, while exercising care to align tab on insert with hole in pump body. Remove all excess Perfect Seal. DO NOT allow any excess Perfect Seal to remain inside of insert, or impeller will become damaged. 6. Install water tube seal and lubricate inside of seal with Multipurpose Lubricant (C-92-63250), then insert water inlet tube guide. INSTALLATION 1. Install gasket on water pump base. 2. Lubricate pump base "0 " ring and oil seal lips with Multipurpose Lubricant (C-92-63250). 3. Wrap tape around drive shaft "0 " ring groove to protect oil seals and slide water pump base over drive shaft and into gear housing. 4. Install lower gasket on water pump base, then face plate (hp down) and upper gasket. (Figure 10) 5. Install impeller drive key in slot provided on drive shaft. Multipurpose Lubricant may be used to hold key in position until pump impeller is installed. 6. Slide impeller over drive shaft and align impeller key slot with key, then seat impeller on face plate. 7. To ease installation, lubricate oil seal lip with Multipurpose Lubricant. Lubricate water pump insert with mixture of soap and water. Place water pump body assembly over impeller and push water pump body down while rotating drive shaft clockwise to help impeller enter pump body. Water Pump Body Drive Shaft Face Plate Figure 10. Water Pump Parts Identification 8. Install washers, screw and nuts. Torque screw and nuts to specifications. (Figure 11) IMPORTANT: Water pump MUST be torqued to specifications, or water pump failure may result. 9. Install centrifugal slinger and drive shaft "0 " ring. Plastic Water Tube Guide to 20 Lbs. Figure 11. Water Pump Assembly Installed 6A-12 - MERCRUISER DRIVE SYSTEMS GEAR HOUSING INSTALLATION NOTE: If water inlet tube was removed, coat tube upper end with Multipurpose Lubricant (C-92-63250) and install in drive shaft housing. i. Apply light coat of Multipurpose Lubricant on bottom end of water tube and heavy coat of lubricant on drive shaft splines. 2. Insert alien head trim tab screw in place on top of gear housing. 3. Install seal in groove around gear housing to drive shaft housing inter-connecting oil passage. 4. Shift gear housing assembly into full forward gear. 5. Check that upper shift shaft (located in drive shaft housing) is in full forward position. NOTE: Gear housing assembly may be held in forward gear by applying slight pressure to propeller shaft in counterclockwise direction. 6. While installing gear housing, align water tube with water tube guide and drive shaft splines with upper drive shaft and shift shaft splines. 7. Rotate propeller shaft counterclockwise to help drive shaft splines enter upper drive shaft splines. NOTE: If propeller shaft is rotated in clockwise direction before shift shafts are coupled, gear housing must be shifted back into forward gear. 8. With 2 housings joined, install and tighten elastic stop nuts and alien head screw. (Figure 1) 9. Install trim tab and torque alien head screw to specifications, then install plastic plug. (Figure 1) 08058 Figure 1. Propeller and Gear Housing Installation Figure 3. Vent Plug in Drive Shaft Housing NOTE: Refer to trim tab adjustment in Section 1, "General Information ". 10. Install thrust hub. propeller, splined washer, tab washer and propeller nut. (Figure 1) 11. Place block of wood between propeller and anti-cavitation plate to prevent propeller from turning while torquing propeller nut. Bend tab washer tabs into slots provided on splined washer to lock propeller nut. 12. Fill drive unit with Quicksilver Super-Duty Gear Lubricant (C-92-63225) through fill hole in gear housing (Figure 2) until lubricant runs out of vent hole in drive shaft housing. (Figure 3) MERCRUISER DRIVE SYSTEMS -6A-13 (38494 Figure B. Drive Shaft Housing Parts Identification 6A-14 - MERCRUISER DRIVE SYSTEMS DRIVE SHAFT HOUSING REMOVAL Refer to Section 2, "Removal-Installation-Alignment" for removing drive unit from transom plate assembly. DRIVE SHAFT HOUSING DISASSEMBLY Remove gear housing assembly from drive shaft housing. Refer to "Gear Housing Removal" (see "Index"). TOP COVER and WATER POCKET COVER REMOVAL overheating, uneven wear and embedded foreign metal particles. Replace bearing cup and bearing, if any of these 1. Remove water tube from water pocket cover. exist. 2. Remove screws from water pocket cover (located inside 3. Inspect top cover "0 " ring for cuts, nicks, hardness and lower end of drive shaft housing) and remove cover and cracks. If "0 " ring serviceability is doubtful, replace "0 " gasket. ring. 3. Remove 4 screws which hold top cover assembly to drive 4. Replace all damaged shims with new shim of same shaft housing. thickness. 4. Remove top cover assembly by lifting and turning cover DISASSEMBLY slightly. (Prying slots are provided.) CLEANING and INSPECTION 1. Remove upper drive shaft bearing cup from top cover with 1. Clean parts in solvent and dry with compressed air. Slide Hammer Puller (C-91-34569A1). 2. Check upper drive shaft top bearing cup (located in top 2. Remove "0 " ring from top cover. cover) for pitting, grooves, scoring, discoloration from 3. Remove rubber seal from water pocket cover. UNIVERSAL JOINT, DRIVE GEAR and BEARING ASSEMBLY REMOVAL 1. Loosen universal joint tapered roller bearing retainer by turning counterclockwise with Bearing Retainer Wrench (C-91-36235). (Figure 1) 2. Pull straight out on universal joint to remove universal joint, drive gear and bearing assembly. 3. Remove shims which may adhere to bearing cup and/or shoulder in drive shaft housing. Figure 2. Removing Universal Joint Shaft Nut DISASSEMBLY NOTE: Assembly mast be disassembled to obtain proper cleaning and inspection. 1. Place one end of suitable bar in vise and other end through universal joint yoke (for holding assembly) and remove nut. 2. Lift drive gear and bearing assembly from universal joint shaft. 977 R2 MERCRUISER DRIVE SYSTEMS - 6A-15 UPPER DRIVE SHAFT and DRIVEN GEAR ASSEMBLY REMOVAL CLEANING and INSPECTION Lift upper drive shaft and gear assembly from drive shaft 1. Inspect driven gear for pitting, chipped or broken teeth housing. and excessive or uneven wear. Replace gear if any of these exist. CAUTION: DO NOT switch drive gear tapered roller bearings and cups. Bearing must stay with its original bearing cup. Bearings also should be installed on gear in same order as removal. If bearing replacement is necessary, both bearings and small and large spacers must be replaced as an assembly to ensure correct amount of preload when reassembled. 3. Lift retainer ring, "0 " ring, oil seal carrier with oil seal, tapered roller bearings and spacers from drive gear. 4. Remove universal joint oil seal from oil seal carrier. 5. Using a punch and hammer, drive off universal joint bearing snap rings. (Figure 3) 6. With suitable adaptor to support universal joint yoke, press on one bearing until opposite bearing is pressed into adaptor. Remove loose bearing. (Figure 4) Figure 3. Removing Universal Joint Bearing Snap Rings Figure 4. Removing First Universal Joint Bearing 07748 Figure 5. Removing Second Universal Joint Bearing 7. Turn universal joint assembly 180° and press on bearing cross-member to remove second bearing. (Figure 5) Remove each pair of bearings in this manner. 8. Remove 2 "0 " rings from coupling end of universal joint shaft. CLEANING and INSPECTION 1. Clean all parts in solvent and dry with compressed air. 2. Inspect splines on both coupling and gear end of universal joint assembly for wear. 3. Clean all corrosion from coupling end. If splines are partially corroded away, replace (coupling end) yoke. NOTE: If universal joint coupling end splines are corroded or worn, also inspect engine coupling splines. Lubricate universal joint spline and engine coupling splines with Multipurpose Lubricant (C-92-63250) before drive unit installation. 4. Inspect shaft (between yoke and splines) on gear end * universal joint for groove were oil seal rides. If shaft is grooved, install NEW oil seal and NEW yoke on universal joint. 5. Check universal joint bearings for excessive looseness. If bearings are worn or pitted from presence of water in bellows, replace cross and bearing assemblies. CAUTION: Use only Universal Joint Lubricant (C-92-68409) for lubricating universal joint bearings. 6. Inspect drive gear for pitting, chipped or broken teeth and excessive or uneven wear. Replace gear if any of these exist. 7. Check tapered roller bearings by inspecting bearing cups. Replace bearings and bearing cups if cups are pitted, grooved, scored, worn uneven, discolored from overheating or have foreign metal particles embedded in cup. 8. Inspect oil seal for wear, tears, roughness and proper spring position. If oil seal serviceability is doubtful, replace oil seal. 9. Inspect "0 " rings for cuts, nicks, hardness and cracks. If "0" ring serviceability is questionable, replace "0" ring. 10. Replace all damaged shims with new shims of same thickness. 6A-16 - MERCRUISER DRIVE SYSTEMS 2. Replace tapered roller bearings and bearing cups if cups are pitted, grooved, scored, worn uneven, discolored from overheating or have foreign metal particles embedded in the cup. 3. Inspect surface of driven gear shaft where oil seal lip contacts the shaft. Any groove in shaft in this area requires oil seal and gear replacement. DISASSEMBLY CAUTION: DO NOT remove bearings unless replacement is necessary. 1. Use Universal Puller Plate (C-91-37241) and arbor press to remove tapered roller bearing from driven gear. (Figure 6) Upper Drive Shaft Bearing Assembly Appropriate Tool Figure 6. Removing Driven Gear Bearing 2. With Universal Puller Plate (C-91-37241) placed under upper drive shaft bearing and using an appropriate tool, press bearing from drive shaft on an arbor press. (Figure 7) 3. Support driven gear with Universal Puller Plate or proper tool, and press upper drive shaft from driven gear with appropriate tool. (Figure 8) 4. Remove "0 " ring from lower end of upper drive shaft. BEARING CUP (DRIVEN CLEANING and INSPECTION 1. Inspect oil seals for wear, tears, roughness and proper spring position. If oil seal serviceability is doubtful, replace oil seals. 2. Check bearing cup for pitting, grooves, scoring, discoloration from overheating, uneven wear and embedded Figure 7. Removing Upper Drive Shaft Bearing Appropriate Tool Pinion Gear Figure 8. Removing Upper Drive Shaft from Driven Gear GEAR) and OIL SEALS foreign metal particles. Replace bearing cup and bearing if any of these exist. REMOVAL 1. Use Slide Hammer Puller (C-91-34569A1) to remove driven gear bearing cup and oil seals. 2. Remove driven gear bearing cup shims. INTERMEDIATE SHIFT SHAFT REMOVAL 1. Remove intermediate shift shaft retaining cotter pin and washer, then remove shift shaft. 2. Drive out shift shaft bushing, if replacement is necessary. DRIVE SHAFT CLEANING and INSPECTION 1. Clean assembly in solvent and dry with compressed air. INSPECTION Check shift shaft for bent condition. Shift shaft may be bent if installation of drive unit is attempted without drive unit shifted into forward gear position. HOUSING 2. Check housing carefully for impact damage. 3. Check for loose fitting bearing cups. 4. Inspect condition of housing painted surface. MERCRUISER DRIVE SYSTEMS -6A-17 DRIVE SHAFT HOUSING REASSEMBLY BEARING CUP (DRIVEN GEAR) and LOWER OIL SEAL INSTALLATION 3. Install lower drive shaft housing oil seal with lip facing driven gear. 1. Install same amount of shims (that were removed) into drive shaft housing driven gear tapered roller bearing cup cavity. 2. Drive or press driven gear bearing cup into housing with NOTE: DO NOT install upper oil seal until upper drive Bearing Cup Driver (C-91-33493). shaft preload is set. UPPER DRIVE SHAFT and DRIVEN GEAR ASSEMBLY REASSEMBLY 1. Place "0 " ring on driven gear end of upper drive shaft. 2. Press upper drive shaft into driven gear. (Figure 1) 3. Use appropriate adaptor, so that pressing force will be applied to inner race of bearings, and install upper drive shaft and driven gear bearing. INSTALLATION Set upper drive shaft and gear assembly into drive shaft housing. NOTE: For shimming procedures, refer to "Top Cover and Top Oil Seal - Installation ", following. Figure 1. Pressing Upper Drive Shaft into Driven Gear TOP COVER and REASSEMBLY 1. Install same amount of shims (that were removed) into top cover, then install upper drive shaft tapered roller bearing cup. 2. Place "0 " ring on cover. INSTALLATION 1. Install cover assembly on drive shaft housing and torque 4 holding screws to specifications while turning shaft. (Correct top cover torque is important to ensure proper bearing preload.) SHIMMING (UPPER DRIVE SHAFT BEARING PRELOAD) a. Insert gear housing drive shaft (with pinion gear nut installed) into upper drive shaft splines. (Figure 2) Use an in. lb. torque wrench (C-9166274) to check upper drive shaft bearing preload at 6 to 10 in. lbs. (6.9 to 11.5kg-cm). b. If reading is too high, shims must be removed from under bearing cup in top cover. If reading is less than specified, shims must be added under bearing cup to obtain proper preload. NOTE: If shim thickness in top cover is changed, top cover again must be torqued before re- measuring drive shaft bearing preload. TOP OIL SEAL 977R1 6A-18 - MERCRUISER DRIVE SYSTEMS 2. With bearing preload correct, top oil seal may be installed with lip facing toward driven gear. Use Oil Seal Driver (C-91-33490). SHIMMING (DRIVEN GEAR) a. With bearing preload correct and top cover torqued to specifications, place Shimming Tool (C-91-60526) into drive gear and bearing assembly cavity. (Figure 3) See chart (following) for correct position of shimming tool to be used. Shimming Tool (C-91-60526) 08488 Figure 3. Measuring Driven Gear Clearance tween one outside tooth of aligned gear teeth and shimming tool. Rotate shimming tool to obtain light drag on feeler gauge. Then (without moving shimming tool), insert feeler gauge between shimming tool and other outside tooth of aligned gear teeth. c. If clearance is larger than feeler gauge being used, repeat preceding procedure (Step "b"), using thicker feeler gauge until same clearance is obtained between both outside gear teeth and tool. d. If clearance is smaller than feeler gauge being used, repeat preceding procedure (Step "b"), using thinner feeler gauge until same clearance is obtained between both outside gear teeth and tool. NOTE: The preceding procedure will position shimming tool face parallel with face of gear and obtain correct reading of clearance between gear and shimming tool e. Correct clearance is .025" (,64mm). If clcarance on gear being checked is less than .025", subtract clearance reading, that you have, from .025" and remove shims of that thickness from under driven gear tapered roller bearing cup. Also add shims of same thickness under upper drive shaft tapered SHIMMING TOO L (C-91-60526) Tool Position X Y Z Drive Unit Model 165 120-140 -470 V-8's roller bearing cup to maintain bearing preload. Recheck clearance. f. If clearance is more than .025", subtract .025" from clearance reading, that you have, and add shims of that thickness under driven gear tapered roller bearing cup. Also remove shims of same b. Align proper shimming tool face (X-Y or Z) with thickness under upper drive shaft tapered roller 2 or 3 teeth (depending upon gear ratio) of driven bearing cup to maintain bearing preload. Recheck gear. Insert feeler gauge (.025" [,64mm]) be-clearance. UNIVERSAL JOINT, DRIVE GEAR and BEARING ASSEMBLY REASSEMBLY IMPORTANT: Use only Universal Joint Lubricant (C-92-58229) for lubricating universal joint bearings. 1. Place universal joint bearing cups in yoke and start them on bearing cross-members. Finish installation by pressing bearings through yoke and onto cross-members. (Figure 4) 2. Install bearing cup retaining snap rings. (Figure 5) Figure 5. Installing Bearing Cup Snap Rings 3. Install each pair of bearings in this manner. 4. Install two "0 " rings in grooves provided on coupling end of universal joint shaft. 5. Press oil seal into oil seal carrier (with lip of seal facing concave side of carrier) until seal is flush with carrier. Lubricate lip of seal with Multipurpose Lubricant (C-92-63250). 07746 977 R2 MERCRUISER DRIVE SYSTEMS - 6A-19 6. Place tapered roller bearing on gear, small and large spacer, second tapered roller bearing, oil seal carrier assembly, "0 " ring and ring. (Figure 6) C-91-60523 Tapered Roller Bearing 06917 Figure 8. Measuring Drive Gear Clearance Oil Seal Carrier Tapered Roller Bearing ^arin901U|05 Figure 6. Bearing Set Parts Identification 7. Place one end of suitable bar in vise and other end through universal joint yoke for holding. Place bearing retainer nut, drive gear and bearing assembly onto universal joint assembly. Place washer (concave side facing drive gear) and nut on universal joint shaft. Be sure that preload spacer is centered and does not protrude past bearing cups. Torque nut to specifications while turning bearings. NOTE: The torque on universal joint shaft nut applies correct preload on drive gear bearing assembly. Make sure that torque is correct. SHIMMING TOOL (C-91-60523) Tool Position X Y z Drive Unit Model 120-140 (Serial No. 2791956 and Below) 120-140 (Serial No. 2791957 and Above) 165 and 470 V-8's b. Align proper shimming tool face (X-Y or Z) with 2 or 3 teeth (depending upon gear ratio) of driven INSTALLATION gear. Insert feeler gauge (.025" [.64mm]) between one outside tooth of aligned gear teeth and 1. Remove top cover assembly. shimming tool. Rotate shimming tool to obtain 2. Place universal joint tapered roller bearing cup to drive light drag on feeler gauge, then (without moving shaft housing shims into housing cavity. shimming tool) insert feeler gauge between shimming tool and other outside tooth of aligned gear teeth. CAUTION: MerCruiser drive units with same number c. If clearance is larger than feeler gauge, which is of teeth on both gears (in drive shaft housing) have being used, repeat preceding procedure (Step identification marks on drive and driven gears. These "b"), using thicker feeler gauge until same clear- marks must be matched as shown in Figure 7, ance is obtained between both outside gear teeth whenever gears are installed into drive shaft housing. and tool. d. If clearance is smaller than feeler gauge (being used), repeat preceding procedure (Step "b"), using thinner feeler gauge until same clearance is obtained between both outside gear teeth and tool. NOTE: The preceding procedure will position shimming tool face parallel with face of gear and obtain correct reading of clearance between gear and shimming tool. Correct clearance is .025". If clearance on gear 3. Install universal joint and drive gear assembly into drive being checked is less than .025", subtract clear- shaft housing. Torque bearing retainer nut to specifi-ance reading, that you have, from .025" and add cations. shims of that thickness between universal joint tapered roller bearing cup and drive shaft housing. Recheck clearance. SHIMMING (DRIVE GEAR) If clearance is more than .025", subtract .025" from clearance reading, that you have, and a. Place Shimming Tool (C-91-60523) into drive remove shims of that thickness from between shaft housing top cover cavity. (Figure 8) See universal joint tapered roller bearing cup and chart (following) for correct position of shimming drive shaft housing. Recheck clearance. tool to be used. Figure 7. Matching Gear Identification Marks 4. Reinstall top cover assembly and torque to specifications. 977 R1 6A-20 - MERCRUISER DRIVE SYSTEMS INTERMEDIATE SHIFT SHAFT INSTALLATION 2. Place shift shaft thru bushing and install washer and cotter pin. 1. Drive shift shaft bushing into drive shaft housing. WATER POCKET COVER REASSEMBLY INSTALLATION Install rubber seal in water pocket cover. Lubricate seal with 1. Place NEW gasket and water pocket cover in position on Multipurpose Lubricant (C-92-63250). drive shaft housing. 2. Install screws and torque to specifications. DRIVE SHAFT HOUSING INSTALLATION 1. Install gear housing assembly onto drive shaft housing, 2. To install drive shaft housing to transom plate assembly, following instructions under "Gear Housing Installation" refer to Section 2, "Removal-Installation-Alignment". (see "Index"). MERCRUISER DRIVE SYSTEMS - 6A-21 HYDRAULIC POWER TRIM TRANSOM PLATE ASSEMBLY Without Side-Mounted Rotary Switch (Figure A) Figure A. Transom Plate and Drive without Side-Mounted Rotary Switches S 04604 GIMBAL HOUSING BALL BEARING Figure 1. Removing Bearing Cartridge Assembly INSPECTION 1. Remove drive unit from bell housing, as outlined in "Removal", Section 2. 2. Reach thru bell housing and rotate bearing to check for rough spots. Pull and push on inner race to check for side wear. Any excessive movement is cause for replacement. Figure 2. Installing Bearing Cartridge Assembly REMOVAL CAUTION: Gimbal bearing may be damaged during removal. Do not remove bearing cartridge assembly unless replacement is necessary. Replacement bearings come as an assembly with cartridge and must be replaced as an assembly. 6A-22 - MERCRUISER DRIVE SYSTEMS 977 R1 1. Remove drive unit from bell housing as outlined in 2. Install bearing cartridge assembly with tools illustrated in "Removal" Section 2. Figure 3. 2. Remove snap ring (if installed) with Ring Pliers 3. Insert Driver Head (C-91-32325) thru Mandrel (C-91-37240A1). (C-91-30366) and into inside diameter of bearing 3. Remove bearing cartridge assembly with tools illustrated in assembly. Figure 1. Two (2) plates (C-91-29310) must be used. 4. Align bearing cartridge assembly with gimbal housing Position plates between top and middle studs (located on cavity. Place Plate (C-91-29310) between top and middle bell housing). Use 3-jaw puller from Slide Hammer Puller studs (on bell housing) as a pilot. Drive bearing cartridge (C-91-34569A1). assembly into gimbal housing cavity with a lead hammer or mallet. If bearing assemblv is very tight, it mav be necessarv to tap end of Puller Shaft C-91-31229) with a mallet while 5. Lubricate cartridge gimbal bearing with Pistoluber turning nut (C-ll-24156). (C-91-37299), using ONLY Quicksilver Multipurpose Lubricant (C-92-63250) thru grease fitting. Pump 40 full NOTE: Older Bearing Removal and Installing Kits strokes (1 oz.) to adequately lubricate bearing. (C-91-31229A4) will need 5/8-18 threads cut in un-6. Install snap ring. If gimbal bearing (B-30-60794A2, with threaded portion of Puller Shaft (C-91-31229) to accept tolerance ring) is installed, snap ring can be omitted. slide hammer 3-jaw puller and jaw spreader adaptor. NOTE: Use Engine Alignment Shaft (C-91-48247 or C-91-57797A3) to align gimbal bearing after installation INSTALLATION and check engine alignment. 1. Lubricate outside of cartridge gimbal bearing assembly with Quicksilver Multipurpose Lubricant (C-92-63250). 7. Install drive unit as outlined in "Installation", Section 2. TILT STOP SWITCH ASSEMBLY TESTING With drive unit in the "Down" position, connect continuity meter or test lamp to switch leads. Meter should show continuity or lamp lights. Run Power Trim in "UP" direction until tilt stop switch is actuated. Meter should show NO continuity or lamp should NOT light. Replace switch if defective. REMOVAL 1. Disconnect steering link rod from steering lever. (Figure 3) 2. Support drive unit with an overhead hoist and remove 2 gimbal ring to bell housing hinge pins. 08474 08473 CAUTION: Be careful not to damage gimbal ring roller bearing when driving lower swivel pin with punch. 4. Remove cotter pin from lower swivel pin. (Figure 4) Drive swivel pin down with punch and hammer until cotter pin Figure 4. Lower Swivel Pin and Cotter Pin hole is protruding from gimbal housing. Then, insert small punch or like-object into cotter pin hole (one from each side) and pull pin from housing. 5. Remove 2 screws and stop switch actuating lever. (Figure 5) Figure 3. Steering Lever and Link Rod 3. Operate Power Trim in "up" direction (approximately 5" [12.7cm] cylinder ram movement) and pull bell housing and drive unit assembly away from gimbal housing as far as bellows will allow. Figure 5. Actuator Lever, Allen Screws and Plastic Plugs 977 R2 MERCRUISER DRIVE SYSTEMS - 6A-23 Screwdriver on Brass Pipe Plug '- 08476 Figure 6. Steering Lever and Brass Pipe Plug 6. Remove plug from end of upper swivel shaft (located under switch actuating lever). (Figure 5) 7. Remove upper swivel shaft alien screw and washer from side of gimbal ring. (Figure 5) 8. Remove 2 plastic plugs from upper end of gimbal housing (one each side). (Figure 5) 9- Insert wrenches thru holes (from which plastic plugs were removed) and remove steering lever to upper swivel shaft screw. (Figure 6) 10. Remove brass pipe plug from top of gimbal housing. Drive upper swivel shaft down (using a punch thru pipe plug hole) a sufficient amount to disengage shaft from gimbal housing. (DO NOT drive shaft all-the-way out, or bellows may be damaged.) 11. Pull gimbal ring away from gimbal housing a sufficient amount and remove 2 screws and nuts which secure switch 08477 Figure 7. Tilt Stop Switch 6A-24 - MERCRUISER DRIVE SYSTEMS in gimbal ring. (Figure 7) (Run Power Trim down to aid in positioning gimbal ring.) 12. Remove 2 screws, which hold switch harness to gimbal housing, and remove switch assembly. (Figure 7) INSTALLATION 1. Install new switch in gimbal ring. Switch leads must be positioned as shown in Figure 8, or leads may become shorted to gimbal ring. 2. Insert switch harness thru gimbal housing and install 2 screws which hold switch harness to gimbal housing. (Figure 7) 3. Place gimbal ring in position in gimbal housing. 4. Place shim and steering lever in position (straight forward) and install upper swivel shaft thru steering lever. (If difficulty is encountered when installing shaft, install lower swivel pin to align gimbal ring.) 5. Adjust height of swivel shaft to allow installation of alien screw thru side of gimbal ring. Torque screw to 20 ft. lbs. (2.77mkg). (Figure 5) 04363 Figure 8. Switch Leads Installed 6. Install bolt thru steering arm and torque to 45 ft. lbs. (6.22mkg). (Figure 6) Apply sealer to threads and install plastic plugs (one on each side of gimbal housing). (Figure 5) Install plug in end of upper swivel shaft. Install brass pipe plug in top of gimbal housing. 10. Install switch actuating lever. (Figure 5) 11. Install lower swivel pin, washer and cotter pin. (Figure 4) 12. Check clearance between gimbal ring and gimbal housing at lower swivel pin (.015" to .030" [.38mm to .76mm]). Adjust clearance (if necessary) by adding or removing washers from under steering lever. 13. Run Power Trim in "down" direction until hinge pins can be installed. 14. Install washers, hinge pins and hinge pin retaining pin. 15. Connect steering link rod to steering lever. a. On steering link rod with castle nut, torque nut to 20-25 in. lbs. (23-28.8kg-cm) and, if necessary, back nut off slightly to install cotter pin. (Figure 3) b. On steering link rod with nvlock nut. torque nut to 50-60 in. lbs. (58-69kg-cm). 977 R1 EXHAUST ELBOW and SHUTTER REPLACEMENT REMOVAL 1. After removing drive unit and engine, remove screws and lockwashers from gimbal housing to remove exhaust elbow and "0 " ring(s). (Figures 9 and 10) INSTALLATION 1. Clean mating surfaces on elbow and gimbal housing. 2. Place "0 " ring in groove of gimbal housing. (Figures 11 and 12) 3. Reinstall elbow with screws and lockwashers, torquing them to specification. Be certain that "0 " ring remains seated in groove, properly sealing joint to prevent leakage. Figure 9. Exhaust Elbow and "O" Ring in Groove for In-Line Engine 2. Remove exhaust bellows and remove holding support bracket for water shutter, if replacement is necessary. NOTE: On "V-8" engines, water shutters are located in exhaust separator. Figure 10. Exhaust Separator and Elbows for V-8 Engines Figure 12. "O" Ring Locations for V-8 Engines GIMBAL HOUSING DISASSEMBLY REMOVAL from BOAT Remove gimbal housing and transom plate from boat by referring to"Removal-Installation-Alignmenl" Section 2. MERCRUISER DRIVE SYSTEMS - 6A-25 BELL HOUSING REMOVAL NOTE: Bell housing can be removed with gimbal housing installed on Repair Stand (C-91-33750) or installed on boat. 1. Remove drive unit from bell housing by referring to "Removal-Installation-Alignment" Section 2. 2. . Remove drive unit shift cable from shift plate by removing nut, washer and cotter pin. (Figure 1) Nut and Cotter Figure 1. Drive Unit Shift Cable 3. Remove set screws from cable end guide and remove end guide. (Figure 1) NOTE: Burrs, made by set screws, must be removed from core wire so that inner lining of shift cable will not be damaged when wire is removed. 4. Loosen jam nut on metal cable end and turn metal end out of cable. (Figure 1) 5. Pull support tube from end of inner core wire. 6. Remove protective wrapping from shift cable where cable goes through transom. 7. Cut lock wire and remove alien set screw from end of shift cable slide. (Figure 2) 8. Care must be taken when removing bellows so that bellows are not punctured. If bellows are being replaced, they may be cut and removed from housings after bell housing is removed. Loosen clamp and remove bell housing end of exhaust bellows. Loosen clamp and remove gimbal housing end of universal joint bellows. 9. Remove clamp from rear end of shift cable bellows. 10. Remove cotter pins (one each side) from hinge pins. (Figure 2) Remove 2 hinge pins with Slide Hammer Puller (C-91-34569A1) and Hinge Pin Puller (C-91-36060). 11. Loosen clamp and remove water hose from tube located in gimbal housing. 12. Remove exhaust bellows from gimbal housing with screwdriver through hole provided inside of gimbal housing. (Figure 3) Figure 2. Removing Hinge Pins Figure 3. Removing Exhaust Bellows from Gimbal Housing DISASSEMBLY 1. Remove universal joint bellows, water hose and shift cable from bell housing. 2. Remove rubber bumper if replacement is necessary. 3. It may be necessary to apply heat to shift lever screw to break down Loctite which was used in assembly. Use care when applying heat so that shift shaft oil seal (Figure 4) is not damaged. Remove shift lever screw, then remove shift lever, washer and shift shaft. (Figure 4) 4. Remove shift shaft oil seal and bushing (Figure 4), if replacement is necessary. 5. Remove "0 " ring (located around water passage) (Figure 4) and rubber gasket (located in universal joint passage). (Figure 4) 6A-26 - MERCRUISER DRIVE SYSTEMS CLEANING and INSPECTION 1. Clean all metal parts in solvent and dry with compressed air. 2. If bellows are to In' re-used, remove bellows adhesive from inside diameter of bellows with lacquer thinner. 3. Inspect bellows carefully lor cracks, cuts, punctures and flexibility. If bellows serviceability is doubtful, replace bellows. 4. Clean bellows mounting flanges of bell housing with wire brush or sandpaper, then wipe with lacquer thinner. 5. Check shift cable for cuts or damage caused by cable which is pinched or bent too short. 6. Inspect water hose for cracks, cuts, punctures, worn spots from rubbing and flexibility. 7. Inspect shift shaft oil seal for tears, wear or roughness. 8. Check shift shaft and shift shaft bushings for wear. 9. Check "0 " ring and rubber gasket for cuts, nicks, hardness and cracks. 10. If shift lever roller is worn, replace shift lever assembly. 11. Check rubber bumper for damage. 12. If heat was used to remove shift lever screw, check washer under lever for damage. Figure 4. Shift Shaft Removal GIMBAL RING REMOVAL NOTE: Gimbal ring can be removed with gimbal housing installed on Repair Stand (C-91-33750) or installed on boat. 1. Remove 2 nuts from hydraulic hose connector. (Figure 5) Lower the connector. Remove and cap 2 hydraulic hoses from top of connector. Plug hose connections in connector to prevent losing oil and keep dirt out of hydraulic system. 2. Remove trim cylinder forward anchor pin (Figure 5) and place assembly to the side. Figure 6. Removing Lower Swivel Pin Switch Actuating 01821 Figure 7. Tilt Stop Switch Actuating Lever MERCRUISER DRIVE SYSTEMS - 6A-27 Figure 5. Removing Trim Cylinders 3. Remove cotter pin, lower swivel pin and washer. (Figure 6) 4. Remove 2 screws and remove till stop switch actuating lever. (Figure 7) 5. Remove alien screw from bottom of upper swivel shaft and from top side of gimbal ring. (Figure 8) Figure 8. Preparing for Upper Swivel Shaft Removal Swivel Shaft Puller (C-91-38919) Pktstk Pk»g (One Eoch Side) Slide Hammer Puller 91-34569A1) 08500 Figure 9. Removing Upper Swivel Shaft 6A-28 - MERCRUISER DRIVE SYSTEMS 6. Remove plastic plug (one each side) from gimbal housing. (Figure 8) 7. Disconnect steering link rod from steering arm. 8. Obtain access to steering lever screw and nut through plastic plug holes, then remove screw, nut and steering lever. 9. Use Slide Hammer Puller (C-91-34569A1) and Puller Head (C-91-38919) to pull upper swivel shaft (Figure 9) Remove steering lever and washers (located under steering lever). 10. Remove screws, which hold tilt stop switch wires to gimbal housing, and remove gimbal ring assembly. DISASSEMBLY 1. Remove 2 screws and nuts (Figure 10) and remove tilt stop switch assembly. 01823 Figure 10. Tilt Stop Switch Assembly 2. Drive or press lower swivel pin roller bearing and 2 oil seals out of gimbal ring with Driver (C-91-33492). (Figure 11) NOTE: Oil seals may be pried out of gimbal ring without removing bearing, if bearing replacement is not necessary. - 08499 Figure 11. Lower Swivel Pin Needle Bearing Removal 977 R1 Mounting Screws CLEANING and INSPECTION TILT STOP SWITCH TESTING 1. Clean gimbal ring and bearing in solvent and dry with compressed air. 2. Check surface of lower swivel pin in area where needle bearing rides. Pitting, grooves and uneven wear are causes for bearing and swivel pin replacement. 3. Inspect oil seals for wear, tears and roughness on lip surface. GIMBAL REMOVAL To remove gimbal housing from transom, refer to "RemovalInstallation- Alignment" Section 2. CLEANING and INSPECTION 1. Clean parts in solvent and dry with compressed air. 2. Check gimbal housing ball bearing by rotating inside race of bearing and by checking for rough spots. Check bearing for side wear. Pull and push on inner race. Any excessive movement is cause for replacement. 3. To check upper swivel shaft roller bearing and bushing, NOTE: Switch need not be removed to be tested. Use Power Trim tilting action of drive unit to actuate switch button. 1. Connect continuity meter or test lamp to switch leads. Meter should show continuity,or lamp lights.. 2. Actuate switch button. Meter should show NO continuity or lamp should NOT light. HOUSING inspect area of swivel shaft where bearing and bushing ride. Pitting, grooves and uneven wear are causes for bearing, bushing and swivel shaft replacement. DISASSEMBLY 1. To remove gimbal housing ball bearing, refer to "Gimbal Housing Ball Bearing Removal" (see "Index"). 2. Remove brass pipe plug from top of gimbal housing. Use a punch and hammer (thru plug hole) to remove upper swivel shaft roller bearing, bushing and oil seals. 3. Remove 2 screws from water tube cover and remove cover, rubber bushing and water tube. MERCRUISER DRIVE SYSTEMS - 6A-29 GIMBAL HOUSING REASSEMBLY GIMBAL HOUSING REASSEMBLY 1. Drive bushing and oil seal into gimbal housing with Bushing Driver (C-91-33489). (Figure 1) Oil seal lip faces up. Bushing Install roller bearing and oil seals with Bearing Driver Driver (C-91-33489) (C-9J-33491). Oil seal lip faces up. (Figure 1) or Bearing 3. Install brass pipe plug into gimbal housing. Driver 4. Install water tube thru hole in gimbal housing. Place (C-91-33491) rubber bushing over tube and install cover. 5. For gimbal housing ball bearing installation, refer to "Gimbal Housing Ball Bearing Installation" (see "Index''). INSTALLATION For gimbal housing installation, refer to "RemovalInstallalion- Alijrnmenl" Section 2. Figure 1. Needle Bearing, Bushing and Oil Seal Installation ~ 08498 GIMBAL RING REASSEMBLY 1. Install lower swivel pin roller bearing and oil seals with Bearing Driver (C-91-33492). (Figure 2) Figure 3. Tilt Stop Switch Installation 3. Place washer between gimbal ring and gimbal housing and 08499 install lower swivel pin and cotter pin. (Figure 4) 4. Place shim washers and steering lever in position (straight Figure 2. Installing Swivel Pin Needle Bearing and Oil Seals forward) and install upper swivel shaft thru gimbal ring, gimbal housing and steering lever. 2. When installing tilt stop switch, switch leads must be 5. Adjust height of swivel shaft to allow installation of alien positioned as shown in Figure 3. screw thru side of gimbal ring. Torque screw to specifications. (Figure 5) INSTALLATION 6. Install bolt thru steering arm and torque to specifications. 7. Check clearance between gimbal ring and gimbal housing. 1. Insert switch harness thru gimbal housing and install 2 (Figure 6) Clearance must be between .005" to .030" screws which hold switch harness to gimbal housing. (.13mm to .76mm). Add or remove shim washers under 2. Place gimbal ring in position in gimbal housing. steering lever to correct clearance. 6A-30 - MERCRUISER DRIVE SYSTEMS 04443 01821 Figure 7. Switch Actuating Lever Installation 04443 01821 Figure 7. Switch Actuating Lever Installation Figure 6. Clearance between Gimbal Housing and Ring Switch Ac too ting Figure 5. Upper Swivel Shaft Installation 8. Apply Perfect Seal (C-92-34227) to threads and install plastic plug (one each side of gimbal housing). (FigureS) 9. Apply Perfect Seal to threads and install alien screw in end of upper swivel shaft. (Figure 5) 10. Install switch actuating lever. (Figure 7) 11. Install trim cylinders with cylinder anchor pin. (Figure 8) 12. Install 2 hydraulic hoses to connector and install connector to gimbal housing (Figure 8) with 2 internal lock- washers and 2 nuts (not shown). 13. Connect steering link rod to steering lever. Torque nut to specification and, if necessary, back nut off slightly to Figure 8. Hydraulic Cylinder and Hose Installation install cotter pin. 977 R2 MERCRUISER DRIVE SYSTEMS - 6A-31 BELL HOUSING REASSEMBLY 1. Install shift shaft bushing flush with bottom of housing. 2. Install oil seal with lip facing down. (Figure 9) Bushing Shift Shaft 08501 Figure 9. Shift Shaft Installation 3. Install shift shaft, washer and shift lever. 4. Apply a drop of Loctite "A " (C-92-32609) on threads of locking screw. Install screw thru shift shaft and into shaft lever. (Figure 9) Figure 10. Approximate Hose Clamp Position on Bell Housing 5. Install "0 " ring around water passage and rubber gasket in universal joint passage. (Figure 9) Use a general adhesive hold gasket and "0 " ring in place. 6. Install rubber bumper (if removed). 7. Install shift cable. (Figure 10) 8. Install water hose to bell housing with clamp position, as shown in Figure 10. CAUTION: Before installing universal joint bellows, clean outside diameter of bellows mounting flanges and inside diameter of bellows as illustrated in "Bell Housing Cleaning and Inspection" (see "Index"). WARNING: Extremely Flammable! Vapors from Bellows Adhesive may cause flash fire or ignite explosively. Prevent buildup of vapors. Open all windows and doors. Use only in cross-ventilation. Keep away from heat, sparks and open flame. DO NOT SMOKE. Extinguish all flames and pilot lights and turn off stoves, heaters, electric motors and all other sources of ignition during use and until all vapors are gone. Close container after each use. Contains TOLUOL and petroleum distillates. Harmful or fatal if swallowed. Avoid prolonged contact with skin or breathing of vapors. If swallowed, do not induce vomiting. Call physician immediately. Keep out-of-reach of children. Figure 11. Approximate Hose Clamp Position on Gimbal Housing 9. Apply Bellows Adhesive (C-92-36340A1) to inside diameter of each end of universal joint bellows. .Allow adhesive to dry approximately 10 minutes, or until no longer tacky. 10. Install end of universal joint bellows marked "Aft-Top"' t bell housing. Position clamp as shown in Figure 10 an», torque clamp to specification. 11. Install exhaust bellows and shift bellows to gimbal housing with clamp positioned as shown in Figure 11. Torque clamp to specification. 6A-32 - MERCRUISER DRIVE SYSTEMS INSTALLATION 1. Insert shift cable thru shift cable bellows. 2. Install water hose to tube. 3. Place hose clamps on universal joint and exhaust bellows. 4. Install universal joint bellows over gimbal housing mounting flange. DO NOT tighten clamp at this time. 5. Align washer and hinge pin holes (located in bell housing and gimbal ring: one each side). Use Multipurpose Lubricant (C-92-63250) on washer to hold washer in position during installation. Install hinge pin. 6. Install hinge pin retainer pin and bend retainer pin over in slot provided on front of gimbal ring. 7. Check position of universal joint bellows on gimbal housing mounting flange, to be sure of proper installation, and torque clamp to specification. 8. Install exhaust bellows on bell housing with Expander Tool (C-91-45497A1). (Figure 12) Torque hose clamp to specification. 08508 Figure 12. Installing Exhaust Bellows to Bell Housing 9. Install clamp on rear end of shift cable bellows. End of bellows must be approximately 2" (51mm) from cable connector (located in bell housing). Squeeze clamp securely to prevent water from entering bellows. 10. Tum cable end into shift cable (Figure 13) until it bottoms out, then tighten jam nut. Nut and End Guide Washer Figure 13. Installing Shift Cable 11. Install cable slide and inner core wire. (Figure 14) 12. Install and tighten alien set screw securely, then back off approximately %-turn. The screw must be loose enough to permit core wire to turn or rotate freely, but tight enough to minimize end play between cable and cable slide. Secure screw with lockwire. 13. Install support tube on end of inner core wire approximately Yin (12.7mm) from end of wire. Crimp support tube to secure its position on core wire. 14. Install end guide on cable and tighten set screws securely. (Figure 13) 15. Shift cable assembly is installed as shown in Figure 13. 16. Place protective wrapping on shift cable in area where cable extends thru transom. 17. Install drive unit and adjust shift cables. Refer to "Removal-Installation-Alignment" Section 2. Figure 14. Cable Slide Installation MERCRUISER DRIVE SYSTEMS - 6A-33 HYDRAULIC POWER TRIM TRANSOM PLATE ASSEMBLY With Side-Mounted Rotary Switch (Figure 1) Figure 1. Transom Plate and Drive with Side Mounted Rotary Switch 977 R1 6A-34 - MERCRUISER DRIVE SYSTEMS GIMBAL HOUSING BALL BEARING INSPECTION 1. Remove drive unit from bell housing, as outlined in "Removal" Section 2. 2. Reach thru bell housing and rotate bearing to check for rough spots. Pull and push on inner race to check for side wear. Any excessive movement is cause for replacement. REMOVAL CAUTION: Gimbal bearing may be damaged during removal. Do not remove bearing cartridge assembly unless replacement is necessary. Replacement bearings come as an assembly with cartridge and must be replaced as an assembly. 1. Remove drive unit from bell housing as outlined in "Removal" Section 2. 2. Remove bearing cartridge assembly with tools illustrated in Figure 2. Two (2) plates (C-91-29310) must be used. Position plates between top and middle studs (located on bell housing). Use 3-jaw puller from Slide Hammer Puller (C-91-34569A1). If bearing assembly is verv tight, it may be necessary to tap end of Puller Shaft (C-91-31229) with a mallet while turning nut (C-l 1-24156). NOTE: Older Bearing Removal and Installing Kits (C-91-3I229A4) will need 5/8-18 threads cut in unthreaded portion of Puller Shaft (C-91-31229) to accept slide hammer 3-jaw puller and jaw spreader adaptor. Figure 2. Removing Bearing Cartridge Assembly 977 R2 INSTALLATION 1. Lubricate outside of cartridge gimbal bearing assembly with Quicksilver Multipurpose Lubricant (C-92-63250). 2. Install bearing cartridge assembly with tools illustrated in Figure 3. 3. Insert Driver Head (C-91-32325) thru Mandrel (C-91-30366) and into inside diameter of bearing assembly. 4. Align bearing cartridge assembly with gimbal housing cavity. Place Plate (C-91-29310) between top and middle studs (on bell housing) as a pilot. Drive bearing cartridge assembly into gimbal housing cavity with a lead hammer or mallet. 5. Lubricate cartridge gimbal bearing with Pistoluber (C-91-37299), using ONLY Quicksilver Multipurpose Lubricant thru grease fitting. Pump 40 full strokes (1 oz.) to adequately lubricate bearing. NOTE: Use Engine Alignment Shaft (C-91-48247 or C-91-57797A3) to align gimbal bearing after installation and check engine alignment. 6. Install drive unit as outlined in "Installation" Section 2. MERCRUISER DRIVE SYSTEMS - 6A-35 EXHAUST ELBOW and SHUTTER REPLACEMENT REMOVAL 1. After removing drive unit and engine, remove bolts and lockwashers from gimbal housing to remove exhaust elbow and "O" ring(s). (Figures 4 and 5) (Later 140 and 165 models use 5/16 alien head screws in place of hex head screws.) INSTALLATION 1. Clean mating surfaces on elbow and gimbal housing. 2. Place "0 " ring in groove of gimbal housing. (Figures 6 and 7) - 3. Reinstall elbow with screws and lockwashers, torquing them to specification. Be certain that "0 " ring remains seated in groove, properly sealing joint to prevent leakage. 977 R1 Figure 6. Positioning "O" Ring in Groove on In-Line Engines Figure 4. Exhaust Elbow and "O" Ring in Groove .for In-Line Engine 2. Remove exhaust bellows and remove holding .support . bracket for water shutter, if replacement is necessary. NOTE: On "V-8" engines, water shutters are located in exhaust separator. Figure 5. Exhaust Separator and Elbows for V-8 Engines 6A-36 - MERCRUISER DRIVE SYSTEMS Figure 7. "O" Ring Locations for V-8 Engines TRIM LIMIT SWITCH and TRIM POSITION SENDER NOTE: Trim limit switch (marked "TL") is located on port (left) side of gimbal ring, and trim position sender (marked "TP") is located on starboard (right) side of gimbal ring. If Power Package is not equipped with trim position gauge, trim position sender will be substituted with an empty sender housing which will NOT be marked with a "TP". TESTING Refer to Section 3-D, "Instrumentation". REMOVAL 1. Remove switch and/or sender from gimbal ring by removing 2 screws with lockwasher and retainer. (Figure 8) 2. Remove 2 wires from back of switch and/or sender. Figure 10. Index Marks Aligned (Figure 9) Figure 9. Switch and/or Sender Wires INSTALLATION 1. Fasten wires securely to back of switch and/or sender. (Figure 9) Torque retaining screws to specifications. Fill grooves with Anti-Corrosion Lubricant (C-92-74048). Be sure that the screws are completely covered. 2. Align slots in insulator and position insulator on back of housing assembly. 3. Align rotor index with housing index (Figure 10) and install on gimbal ring with bell housing in "Down" position. 4. Install 2 screws with lockwashers and retainers. (Figure 8) TRIM LIMIT SWITCH ADJUSTMENT Limiting drive unit outward trim travel is necessary to ensure safe control of boat at high speeds and to prevent damage to drive unit or trim cylinders because of lost side support to drive unit. 1. Trim drive unit upward until front edge drive shaft housing of drive unit is protruding %" to 1" (19mm to 25.4mm) into gimbal ring support bosses, as shown in Figure 11. 2. Disconnect limit switch leads from harness (inside boat) and connect leads to continuity meter. 3. Loosen retaining screws which hold trim limit switch. 4. Switch is normally in closed circuit position. Rotate switch housing in either direction until switch circuit just opens. 5. Tighten retaining screws and reconnect switch leads to complete adjustment. Figure 11. Trim Limit Switch Adjustment MERCRUISER DRIVE SYSTEMS - 6A-37 TRIM POSITION SENDER ADJUSTMENT (Accessory) The following procedure is for fine adjustment of instrument needle to bottom of green area on instrument face. 1. Place stern drive unit in full "Down " trim position. 2. Loosen 2 retaining screws (Figure 2) which hold Indicator sender. 3. Turn ignition key to "Run" position. 4. Rotate sender housing in either direction toinstrument needle on bottom of green arc. (Figure 12) 5. Tighten retaining screws. Recheck instrument reading and turn ignition key to "Off " position. Figure 12. Trim Indicator Instrument OUTER TRANSOM ASS'Y DISASSEMBLY REMOVAL FROM BOAT Remove gimbal housing and transom plate from boat by referring to "Removal-Installation-Alignment" Section 2. SHIFT CABLE REMOVAL NOTE: Shift cable can be removed uiith transom assembly installed in boat or removed from boat. 1. If transom assembly is installed in boat, remove shift cable end from shift plate and drive unit from bell housing. Refer to "Removal-Installation-Alignment" Section 2. 2. Remove set screws from cable end guide and remove end guide. (Figure 1) NOTE: If cable is to be reused, burrs (made by set screws) must be removed from core wire so that inner lining of shift cable will not be damaged when wire is removed. 3. Loosen jam nut on metal cable end and turn metal end out Figure 1. Removing Shift Cable of cable. (Figure 1) 4. Pull support tube from end of inner core wire. 7. Remove clamp from aft (rear) end of shift cable bellows. 5. Remove protective wrapping from shift cable (where cable (Figure 2) goes through transom). 6. Cut lockwire and remove alien set screw from end of shift 8. Shift cable can be removed from bell housing at this time, cable slide. (Figure 1) Remove inner core wire and shift however, shift cable is more easily removed after bell cable slide. housing has been removed from gimbal ring. 6A-38 - MERCRUISER DRIVE SYSTEMS 1175 position 04591 CLEANING and INSPECTION 2. Check cable metal end for damaged threads and bent condition. 1. Inspect shift cable for cuts or damage caused by cable 3. Inspect inner core wire for damage and unraveling at end which is bent too short or is pinched. of wire. BELL HOUSING REMOVAL NOTE: Bell housing can be removed with gimbal housing installed on boat. 1. Remove shift cable. See instructions, preceding. 2. Care must be taken when removing bellows so that bellows are not punctured. If bellows are being replaced, they may be cut and removed from housings after bell housing is removed. Loosen clamp and remove bell housing end of exhaust bellows. (Figure 2) Loosen clamp and remove gimbal housing end of universal joint bellows. A block of wood may be used to hold bell housing in tilted-up position while loosening hose clamps. Figure 4. Removing Hinge Pins 4. Position switch and sender assembly so that they will not become damaged during further disassembly. 5. Remove 2 screws, water tube cover and rubber bushing (located at front of gimbal housing) and push water tube thru gimbal housing. 6. Remove gimbal ring to bell housing hinge pins (one each side) with Hinge Pin Tool (C-91-78310). (Figure 4) 7. Remove bell housing assembly. DISASSEMBLY 1. Remove universal joint bellows, water hose and shift cable from bell housing. (Figure 5) 2. Remove rubber bumper, if replacement is necessary. (Figure 5) Water Hose Figure 3. Removing Trim Limit Switch and/or Trim Position Sender 3. Remove 4 screws (2 from each side) and lift trim limit switch and trim position sender from gimbal ring (one each Rubber side). (Figure 3) Bumper NOTE: If trim indicator is not installed in boat, an empty am.— __ wm. 09459 trim position sender housing will be installed on starboard side of gimbal ring. Removal is the same. Figure 5. Front End of Bell Housing 977 R2 MERCRUISER DRIVE SYSTEMS - 6A-39 3. It may be necessary to apply heat to shift lever screw to break down Loctite which was used in assembly. Use care when applying heat so that shift shaft oil seal (Figure 6) is not damaged. Remove shift lever screw, then remove shift lever, washer and shift shaft. (Figure 6) 4. Remove shift shaft oil seal and bushing (Figure 6), if replacement is necessary. 5. Remove "0 " ring (located around water passage) and rubber gasket (located in universal joint passage). (Figure 6) CLEANING and INSPECTION 1. Clean all metal parts in solvent and dry with compressed air. 2. If bellows is to be re-used, remove bellows adhesive from inside diameter of bellows with lacquer thinner. 3. Inspect bellows carefully for cracks, cuts, punctures and flexibility. If bellows serviceability is doubtful, replace bellows. 4. Clean bellows mounting flanges of bell housing with wire brush or sandpaper, then wipe with lacquer thinner. 5. Check shift cable for cuts or damage caused by cable which is pinched or bent too short. 6. Inspect water hose for cracks, cuts, punctures, worn spots from rubbing and flexibility. 7. Inspect shift shaft oil seal for tears, wear or roughness. 8. Check shift shaft and shift shaft bushings for wear. 9. Check "0 " ring and rubber gasket for cuts, nicks, hardness and cracks. 10. If shift lever roller is worn, replace shift lever assembly. GIMBAL RING Figure 6. Aft End of Bell Housing 11. Check rubber bumper for damage. 12. If heat was used to remove shift lever screw, check washer under lever for damage. REMOVAL NOTE: To remove gimbal ring, transom assembly must be removed from boat. 1. To make gimbal ring removal easier, remove exhaust bellows, trim limit switch and trim position sender leads from gimbal housing. (Figure 7) Mounting Studs 09450 09446 Figure 7. Removing Exhaust Bellows 6A-40 - MERCRUISER DRIVE SYSTEMS Figure 8. Removing Trim Cylinders 2. Remove 2 nuts, that retain hydraulic hose connector to gimbal housing (Figure 8), and lower connector. Remove and cap 2 hydraulic hoses from lop of connector. Plug hose connections in connector to prevent losing oil and keep dirt out of hydraulic system. 3. Remove trim cylinder forward anchor pin and remove trim cylinders with hydraulic hoses attached. 4. Pull out retaining cotter pin. lower swivel pin and washer. (Figure 9) 5. Remove alien head pipe plug (located in bottom end of upper swivel shaft). (Figure 10) 977 R1 DISASSEMBLY 1. Drive or press lower swivel pin roller bearing and 2 oil seals out of gimbal ring with Driver (C-91-33492). NOTE: Oil seals may be pried out of gimbal ring without removing bearing, if bearing replacement is not necessary. 2. Remove gimbal ring to bell housing anti-friction washers, if replacement is necessary. Figure 9. Removing Lower Swivel Pin 6. Remove large nut and washer from top of upper swivel shaft and nut and bolt thru steering lever. (Figure 11) 7. Use Slide Hammer Puller (C-91-34569A1) and Puller Head (C-91-38919) to pull upper swivel shaft. (Figure 12) Also remove steering lever and washer (located under steering lever). 8. Remove gimbal ring and washer from between gimbal ring 09451 and gimbal housing. Figure 11. Upper Swivel Shaft and Steering Lever CLEANING and INSPECTION 1. Clean gimbal ring and bearings in solvent and dry with Swivel Shaft compressed air. Poller Head 2. Check surface of lower swivel pin in area where needle bearing rides. Pitting, grooves and uneven wear are causes for bearing and swivel pin replacement. 3. Inspect oil seals for wear, tears and roughness on lip surface. 4. Check gimbal ring to bell housing anti-friction washers for wear. Slide Hammer Poller 09461 Figure 10. Upper Swivel Shaft and Allen Screw Figure 12. Removing Upper Swivel Shaft GIMBAL HOUSING REMOVAL Check gimbal housing ball bearing by rotating inside race of bearing and by checking for rough spots. Check bearing To remove gimbal housing from transom, refer to "Removal-for side wear. Pull and push on inner race. Any excessive Installation-Alignment" Section 2. movement is cause for replacement. 3. To check upper swivel shaft roller bearings, inspect area of CLEANING and INSPECTION swivel shaft where bearings ride. Pitting, grooves and uneven wear are causes for bearing and swivel shaft 1. Clean parts in solvent and dry with compressed air. replacement. 09449 977 R1 MERCRUISER DRIVE SYSTEMS - 6A-41 DISASSEMBLY 2. If upper swivel shaft roller bearing needs replacement, split bearing case with chisel and pry bearing out. 1. To remove gimbal housing ball bearing, refer to "Gimbal 3. Remove 2 screws from water tube cover and remove cover, Housing Ball Bearing Removal" (see "Index"). rubber bushing and water tube. OUTER TRANSOM ASS'Y REASSEMBLY GIMBAL HOUSING I. Drive top small roller bearing into gimbal housing, then install oil seal with lip facing up. 2. Install oil seal (lip facing up), larger roller bearing and second oil seal (lip facing up) with Driver (C-91-33491). (Figure 1) 3. For gimbal housing ball bearing installation, refer to "Gimbal Housing Bali Bearing Installation" (see "Index"). 4. Trim limit switch leads, trim position sender leads, exhaust and shift bellows will not be installed at this time to allow- easier installation of gimbal ring. Refer to "Bell Housing Installation". INSTALLATION For gimbal housing installation to boat, refer to 'RemovalInstallation- Alignment" Section 2. GIMBAL RING REASSEMBLY 1. Install lower swivel pin roller bearing and oil seals (lip facing up) with Driver Tool (C-91-33492). (Figure 2) Figure 4. Swivel Shaft Installation (Aft View) 2. If gimbal ring to bell housing anti-friction washers were removed, epoxy new washers in place, aligning hole in washer with hole in gimbal ring. INSTALLATION 1. Lubricate lip of oil seals and bearing rollers with Multipurpose Lubricant (C-92-63250). Position gimbal ring onto gimbal housing and install washer and lower swivel pin (with slotted end down). (Figure 3) 2. Use screwdriver in slot to turn swivel pin and align cotter pin hole. Install and bend over end of cotter pin. (Figure 3) 3. Lubricate lower swivel pin roller bearing with Multipurpose Lubricant thru grease fitting (located on side of gimbal ring). 4. Insert upper swivel shaft thru gimbal ring and into (but not thru) gimbal housing. (Figure 4) Position washer and steering arm on gimbal housing (Figure 5) and continue to install swivel shaft thru washer and steering arm. As shaft protrudes thru steering arm. 6A-42 • MERCRUISER DRIVE SYSTEMS 178R2 Figure 1. Installing Seals and Roller Bearing 09460 Figure 3. Installing Lower Swivel Pin install washer and nut on shaft. DO NOT tighten nut. Continue shaft installation until bolt can be installed thru steering arm. Install nut on steering arm bolt but do not tighten. 5. Tighten nut on top of swivel shaft (Figure 5) until snap ring (located in groove on swivel shaft) bottoms out on gimbal ring. 6. Install alien head pipe plug (with Perfect Seal) in bottom of swivel shaft. (Figure 4) Tighten plug securely. Figure 5. Swivel Shaft Installation (Front View) 7. Loosen nut on top of swivel shaft (Figure 5) to obtain .005" to .007" (.127mm to ,178mm) between washer and gimbal housing. (Figure 6) 8. Torque steering arm bolt and nut to specifications (Section 8). 9. Install trim cylinders with cylinder anchor pin. (Figure 7) 10. Install 2 hydraulic hoses to connector (gray hose to aft hole in connector) and install connector to gimbal housing, using 2 internal lockwashers and 2 nuts (not shown). (Figure 7) Figure 7. Installing Connector BELL HOUSING 09451 Figure 6. Checking Gimbal Ring to Gimbal Housing Clearance REASSEMBLY 1. Install shift shaft bushing flush with bottom of housing. (Figure 8) Shift Lever Washer Oil Seal Shift Shaft 09458 Figure 8. Bell Housing (Aft End) 977 R2 2. Install shift shaft oil seal with lip facing down. (Figure 8) 3. Position shift shaft, washer and shift lever in bell housing. (Figure 8) Apply a drop of Loctite "A " on threads of shift lever retaining screw. Install screw thru shift shaft and into shift lever. MERCRUISER DRIVE SYSTEMS - 6A-43 4. Install "0 " ring around water passage and rubber gasket in universal joint passage. (Figure 8) Use a general adhesive to hold gasket and "0 " ring in place. 5. Install new rubber bumper (if removed), using Loctite "A " on threads of stud. 6. Apply Perfect Seal to threads of shift cable adaptor and install shift cable to bell housing. 7. Install water hose to bell housing with clamp positioned, as shown in Figure 9. Figure 10. Approximate Hose Clamp Position on Gimbal Housing CAUTION: Before installing universal joint bellows, clean outside diameter of bellows mounting flanges and inside diameter of bellows as illustrated in "Bell Housing Cleaning and Inspection" (see "Index"). WARNING: Extremely Flammable! Vapors from Bellows Adhesive may cause flash fire or ignite explosively. Prevent buildup of vapors. Open all windows and doors. Use only in cross-ventilation. Keep away from heat, sparks and open flame. DO NOT SMOKE. Extinguish all flames and pilot lights and turn off stoves, heaters, electric motors and all other sources of ignition during use and until all vapors are gone. Close container after each use. Contains TOLUOL and petroleum distillates. Harmful or fatal if swallowed. Avoid prolonged contact with skin or breathing of vapors. If swallowed, do not induce vomiting. Call physician immediately. Keep out-ofreach of children. 8. Appl\ Bellows Adhesive to inside diameter of each end of universal joint bellows. Allow adhesive to dry approximately 10 minutes or until no longer tacky. 9. Install end of universal joint bellows, marked "Aft-Top", to bell housing. Position clamp as shown in Figure 9 and torque clamp to specification (Section 8). 10. Install exhaust bellows and shift bellows to gimbal housing with clamp positioned as shown in Figure 10. Torque clamji to specification. 11. Position trim limit switch and trim position sender leads thru gimbal housing and install retaining cover. Tighten screws securely. Position sender and switch wires behind water hose, as shown in Figure 11. 6A-44 - MERCRUISER DRIVE SYSTEMS Figure 11. Correct Routing of Switch and Sender Wires INSTALLATION 1. Insert shift cable end thru shift cable bellows. Multipurpose Lubricant may be used to ease installation. 2. Position water hose tube (attached to water hose) thru gimbal housing with tube end facing upward and slightly tilted to port (left) side for 8-cylinder engine. Face tube end toward starboard (right) side, slightly tilted up from a horizontal position, for 6-cylinder engine. IMPORTANT: Trim position sender and limit switch wires MUST BE positioned as shown in Figure 11. Apply Locquick Primer and Loctite No. 35 to threads of hinge pins, install and torque to specifications. Check position of universal joint bellows on gimbal housing mounting flange, to be sure of proper installation, and torque clamp to specification. Install exhaust bellows on bell housing with Expander Tool (C-91-45497A1). (Figure 12) Torque hose clamp to specification. Expander Tool (3 Pieces) __ 09465 Figure 12. Installing Exhaust Bellows to Bell Housing 977 R1 jm SHIFT CABLE INSTALLATION NOTE: If cable was installed to bell housing previously, omit Step 1. 1. If shift cable is being replaced without removal of bell housing, insert cable end thru aft end of shift cable bellows, using Multipurpose Lubricant to ease installation. Lift up on bottom of bell housing and insert cable end (with connector) thru bell housing opening. Apply Perfect Seal to threads of cable connector and thread cable into bell housing. Tighten connector securely. 2. Install clamp on rear end of shift cable bellows. End of bellows must be approximately 2" (51mm) from cable connector (located in bell housing). Squeeze clamp securely to prevent water from entering bellows. 3. Turn cable end into shift cable (Figure 13) until it bottoms out, then tighten jam nut. 4. Install cable slide and inner core wire. (Figure 13) 5. Install alien set screw in cable slide. Tighten set screw securely, then back off approximately Vi-turn. The screw- must be loose enough to permit core wire to turn or rotate freely, but tight enough to minimize end play between cable and cable slide. Secure screw with lockwire. IMPORTANT: If new inner core wire is being installed, wire must be cut to specified length. Refer to Section 2, "Shift Cable Installation and Adjustment". Figure 13. Installing Shift Cable 6. Install support tube on end of inner core wire approximately JV' (12.7mm) from end of wire. Crimp support tube to secure its position on core wire. 7. Install end guide on cable and tighten set screws securely. (Figure 13) 8. Place protective wrapping on shift cable in area where cable extends thru transom. 9. Install drive unit and adjust shift cables. Refer to "Removal-Installation-AIignment" Section 2. MERCRUISER DRIVE SYSTEMS -6A-45 MANUAL TRIM TRANSOM PLATE ASSEMBLY With Side-Mounted Rotary Switch REPAIR have been eliminated. A mechanical reverse lock assembly, Repair procedures for manual trim model transom plate cutout switch and relay have been added, for which repair assembly are similar to previous model with "hydraulic Power procedures follow. For complete disassembly and reassembly, Trim", preceding, except that all hydraulic Power Trim parts refer to transom plate repair, preceding. TILT (CUTOUT) ROTARY SWITCH TESTING upward travel, switch should close and meter should 1. Switch need not be removed to be tested. With drive unit indicate full continuity. in "Down" position, connect continuity meter to switch wires. Meter should indicate NO continuity. REMOVAL and INSTALLATION Actuate2. switch by releasing reverse lock and manually Refer to "Trim Limit Switch" removal and installation, tilting drive unit up. At approximately 1/3-drive unit preceding. RELAY SOLENOID TESTING terminals. There should be no continuity between bracket 1. Connect ohm meter across solenoid small terminals with and any terminals. wires removed from terminals. 4. Connect continuity meter between solenoid large termi2. An ohm reading of 3.7 to 4.3 indicates a good solenoid. nals. Momentarily apply a minimum of 4.5 volts (but not Replace solenoid if not within specifications. more than 12 volts) to solenoid small terminals. Solenoid 3. Connect continuity meter to solenoid bracket and alter-switch should actuate and meter should indicate full nately to solenoid's 4 terminals with wires removed from continuity across large terminals. REVERSE LOCK ASSEMBLY REMOVAL 1. Remove reverse lock stop screw, washer and spring. (Figure 1) 2. Drive out reverse lock pivot pin. 3. Lift out reverse lock arm assembly. NOTE: DO NOT remove stop assembly (Figure I), unless replacement is necessary. Figure 1. Reverse Lock Assembly and Related Parts 1 - Stop Assembly 2 - Pivot Pin 3 - Washer 4 • Shift Shaft 5 - Cotter Pin 6 - Nut 7 - Washer (2) 8 - Spring (2) 9 - Reverse Hook (2) 10 - Stop Screw 11 - Arm Assembly 12 - Washer 13 - Spring 14 - Bolt 4. If stop assembly removal is necessary, remove gear housing assembly from drive shaft housing. Refer to "Gear Housing Removal" (see "Index"). 5. Remove cotter pin, washer and intermediate shift shaft from drive shaft housing. 6. Lift out stop assembly. CLEANING and INSPECTION 1. Use wire brush to remove any corrosion. Wash parts in solvent and dry with compressed air. 2. Check reverse hooks where they hook over tilt pin (located in gimbal ring) for wear and damage. 3. Check tilt pin for bent condition. Nuts on tilt pin must be slightly loose so that pin can rotate. 4. Inspect surface of stop assembly where stop contacts reverse hooks when shifted into reverse. If surface is worn, replace stop assembly. D. Check stop assembly nylon roller for wear. Replace stop assembly if needed. INSTALLATION 1. Place stop assembly in drive shaft housing. DO NOT install pivot pin. 2. Insert shift shaft thru its bushing in drive shaft housing and install washer and cotter pin. Bend open cotter pin. 3. Position arm assembly into drive shaft housing (with reverse hooks facing down), aligning pivot pin holes in stop assembly and arm assembly with holes in drive shaft housing. Install pivot pin and peen drive shaft housing in area around pivot pin holes (on each side) to secure pin. 4. Place spring and washer under arm assembly and install stop screw. Tighten screw until screw shoulder bottoms out on drive shaft housing. 5. Install gear housing assembly. Refer to "Gear Housing Installation" (see "Index"). 6A-46 - MERCRUISER DRIVE SYSTEMS SECTION 6 • DRIVE SYSTEMS PART B - MERCRUISER D-TR DRIVE UNIT A BRUNSWICK COMPANY ' '' • ' -V ; . -fc INDEX Page MerCruiser H-TR Drive Unit Service Recommendations . . . -6B-1 Gear Housing Assembly 6B-2 Gear Housing Removal 6B-3 Gear Housing Disassembly - Right Hand Rotation 6B-3 Bearing Carrier (Carrier Retainer & Tab Washer) 6B-3 Removal 6B-3 Cleaning and Inspection 6B-4 Disassembly 6B-4 Propeller Shaft Assembly ("O" Ring, Thrust Ring and Load Ring) 6B-4 Left Hand Rotation Variations 6B-4 Removal 6B-5 Cleaning and Inspection 6B-5 Disassembly (Right Hand Rotation) 6B-5 Drive Shaft Assembly & Pinion Gear 6B-6 Removal 6B-6 Cleaning and Inspection 6B-6 Disassembly 6B-7 Tapered Roller Bearing Cup (Drive Shaft and Propeller Shaft 6B-7 Removal 6B-7 Cleaning and Inspection 6B-7 Roller Bearing (Drive Shaft) 6B-8 Removal 6B-8 Cleaning and Inspection 6B-8 Gear Housing 6B-8 Cleaning and Inspection 68-8 Gear Housing Reassembly (Right Hand Rotation) 6B-8 Roller Bearing (Drive Shaft) 6B-8 Installation 6B-8 Tapered Roller Bearing Cup (Drive Shaft and Propeller Shaft) 6B-9 Installation 6B-9 Drive Shaft Assembly & Pinion Gear 6B-9 Reassembly 6B-9 Installation 6B-9 Shimming (Pinion Gear) 6B-9 Propeller Shaft Assembly (Right Hand Rotation) 6B-9 Reassembly 6B-10 Installation 6B-10 Bearing Carrier Assembly ("O" Ring, Thrust Ring and Load Ring) 6B-10 Reassembly 6B-10 Installation ........6B-11 Shimming (Gear Backlash) 6B-11 Gear Housing Installation 6B-12 Drive Shaft Housing Assembly 6B-13 Drive Shaft Housing Removal 6B-14 Drive Shaft Housing Disassembly 6B-14 Bearing Cup (Lower Drive Shaft), Shims, Spacer and Coupling , 6B-14 Removal 6B-14 Cleaning and Inspection 6B-14 Top Cover, Rear Cover and "O " Rings 6B-14 Removal 6B-14 Cleaning and Inspection 6B-14 Universal Joint 6B-15 Removal 6B-15 Cleaning and Inspection Disassembly Drive Gear, Shims, Tab Washer and Spacer Removal Cleaning and Inspection Disassembly Bearing Cup, Oil Seal (Universal Joint) and "O " Ring Removal Cleaning and Inspection Drive Shaft, Driven Gear, Bearings and Check ValveRemovalCleaning and InspectionDisassembly Drive Shaft HousingCleaning and InspectionDrive Shaft Housing ReassemblyBearing Cup (for Driven Gear and Drive Shaft) InstallationDrive Shaft and Driven Gear AssemblyReassemblyInstallationShimming (Driven Gear) Oil Seal (Universal Joint) InstallationBearing Cup (Universal Joint Front Bearing) Installation Drive Gear Assembly Reassembly Installation Universal Joint Reassembly Installation Shimming (Drive Gear) Drive Shaft Housing InstallationGimbal Housing Disassembly Removal from Boat Bell Housing Removal Cleaning and Inspection Gimbal Ring Removal Cleaning and Inspection 6B-25 Gimbal Housing 6B-25 Disassembly 6B-25 Cleaning and Inspection 6B-25 Gimbal Housing Reassembly 6B-26 Gimbal Housing 6B-26 Reassembly 6B-26 Gimbal Ring 6B-26 Reassembly 6B-26 Installation 6B-26 Bell Housing 6B-26 Reassembly 6B-26 Installation 6B-26 Trim Switch and Trim Sender Installation 6B-27 Trim Limit Readjustment 6B-27 Trim Indicator Sender Adjustment 6B-27 Page 6B-15 6B-15 6B-16 6B-16 6B-16 6B-16 6B-17 6B-17 6B-17 6B-17 6B-17 6B-18 6B-18 6B-19 6B-19 6B-19 6B-19 6B-19 6B-19 6B-19 6B-19 6B-20 6B-20 6B-20 6B-21 6B-21 6B-21 6B-21 6B-21 6B-21 6B-21 6B-22 6B-22 6B-23 6B-23 6B-23 6B-23 6B-23 6B-24 6B-24 6B-24 MERCRUISER II-TR DRIVE UNIT SERVICE RECOMMENDATIONS Instructions are printed in the sequence which will be followed to assure best results when removing or replacing components. Follow "Disassembly" and "Reassembly" procedures as written. If complete disassembly is not necessary, however, start reassembly at point disassembly was stopped. (Use "Index".) In order to assure correct and durable operation after assembly, it is important that all adjustments and torque value specifications be maintained to the highest degree of accuracy. Use special service tools, where specified, and use common tools of proper fit when removing and replacing parts. When holding housings or parts in a vise -- or by other means -use blocks of wood and/or brass shields to prevent marring parts' surfaces. Pressed-on parts (bearings, gears, etc) require adapting appropriate mandrels and supports for the press used. Do not apply force on the bearing cages, mating surfaces or edges which will mar or fail if force is applied. DO NOT spin bearings with compressed air, as bearings may be damaged, and it can be dangerous. To prevent corrosive action, apply Perfect Seal (C-92-34227) to external parts of bearing carrier, bearing carrier retainer and housing mating surfaces during reassembly. DO NOT allow sealer to contact "0 " rings or enter bearings and gears. To ease installation of drive unit components, applv Multipurpose Lubricant (C-92-63250) to the lip of all oil seals and "0 " rings. To prevent oil leakage, apply Loctite Type "A" (C-92-32609-1) on outside diameter of all metal case oil seals. When using Loctite on oil seals or threads, surfaces must be clean and dry. Refer to Section 8, "Specifications", for all torque specifications. Keep a record of shim amounts and location. Be sure to follow slumming instructions closely. Gears must be mounted to correct feeler gauge reading and correct gear backlash to avoid noisy performance and premature failure. Bearing preload must be within specifications, or bearing failure may result. Threaded parts are right hand (RH), unless otherwise indicated. Drive unit should be completely disassembled, inspected and cleaned, if either gear housing or drive shaft housing has indicated a failure. A suitable mandrel for pressing tapered roller bearings on shafts and gears can be obtained from the old bearing. Cut outer cage off inner race with hack saw. (Figure A) Remove cage and bearing rollers. Inner race (used as a mandrel) will apply pressing force to inner race of new bearing without damaging bearing cage, rollers or races. Remove bearings from gears or shafts only if replacement is necessary. 977R1 MERCRUISER DRIVE SYSTEMS -6B-1 GEAR HOUSING ASSEMBLY Figure B. Gear Housing Parts Identification (Right Hand Rotation) 6B-2 - MERCRUISER DRIVE SYSTEMS GEAR HOUSING REMOVAL 1.2.3.4. Remove complete drive unit from bell housing as in "Drive Shaft Housing Removal", Section 2. Drain gear lubricant. Check lubricant for metal particles or water. a. If metal particles are found, disassemble complete drive unit. Clean all parts in solvent (especially bearings) and dry with compressed air. b. If water is found, disassemble complete drive unit. Clean all parts in solvent and dry with compressed air. Apply a light coat of oil to all parts to prevent rusting. Check housings for impact damage and replace all "0 " rings and oil seals. Remove propeller and trim tab. Remove alien head screw located under trim tab. Remove 7 nuts and separate gear housing from drive shaft housing. Figure 1. Draining Lubricant GEAR HOUSING DISASSEMBLY - RIGHT HAND ROTATION IMPORTANT: Follow "General Service Recommendations" (see "Index"). BEARING CARRIER (CARRIER RETAINER and TAB WASHER) IMPORTANT: Before disassembly, position dial indicator on machined surface of propeller shaft just behind bearing carrier. Push propeller shaft to one side and hold in this position while zeroing dial indicator. Move propeller shaft Tool (C-91-54873) to opposite side. Shaft deflection should be max..003" (.076mm). DO NOT turn propeller shaft. Repeat procedure, moving shaft up-and-down. If shaft deflection is more than .003", shaft and/or needle bearing is worn, or propeller shaft is undersize. REMOVAL 1. Mount gear housing assembly on Repair Stand (C-91-33750) with Adaptor (C-91-60524A1). 2. Straighten locking tab and loosen threaded retainer with c C Retainer Tool (C-91-54873). (Figure 1) Remove retainer and tab washer. 3. Remove bearing carrier with Slide Hammer (C-9134569A1) and Bearing Carrier Puller (C-91-45086A1). (Figure 2) Be careful not to lose carrier alignment key. Figure 1. Removing Threaded Retainer MERCRUISER DRIVE SYSTEMS - 6B-3 2. Check propeller shaft bearing cup for pitting, grooves, scoring, discoloration from overheating, uneven wear and embedded foreign metal particles. Replace bearing cup and bearing if any of these exist. 3. Inspect oil seals for wear, tears, roughness and prope. spring position. If there is any doubt about oil seal serviceability, replace oil seals. Inspect surface of propeller shaft where oil seal lips contact shaft. (Figure 3) Any groove in propeller shaft in this area requires oil seals and shaft replacement. 4. Check needle bearing for serviceability by inspecting bearing contact surface on propeller shaft. (Figure 3) Pitting, grooves, scoring, discoloration from overheating, uneven wear and embedded foreign metal particles are reason for bearing and propeller shaft replacement. 5. Check threaded retainer for broken or corroded threads and cracks. 6. Replace tab washer. DO NOT re-use. DISASSEMBLY 1. Using Slide Hammer Tool (C-91-34569A1), remove tapered roller bearing cup from bearing carrier. (Figure 4) CLEANING and INSPECTION 1. Clean assembly in solvent and dry with compressed air. DO NOT allow solvent to remain on oil seals, or seals will become unserviceable. Figure 2. Removing Bearing Carrier Oil Seal Surface Bearing Surface 07556 Figure 3. Propeller Shaft Surface Figure 5. Removing Seals and Bearing 2. Using Sleeve Tool (C-91-55919) and Driver Rod Tool (C-91-37323). remove needle bearing and 2 oil seals from carrier. (Figure 5) NOTE: Seals can be removed separately with Slide Hammer (C-91-34569.4/). PROPELLER SHAFT ASSEMBLY ("O" RING, THRUST RING and LOAD RING) LEFT HAND ROTATION VARIATIONS bearing have part numbers different than right hand rotation parts. These parts are not interchangeable and are 1. Left hand propeller shaft, front bearing and driven gear assembled differently, as shown in Figure 6. 6B-4 - MERCRUISER DRIVE SYSTEMS Right Hand Left Hand 07539 Figure 6. R.H. and L.H. Propeller Shaft Assemblies 2. Driven gear on left hand rotation is not a press fit to propeller shaft and is installed into gear housing before pinion gear is installed. Propeller shaft then is set into driven gear. 3. Gear shimming and preload are adjusted at same locations for left hand and right hand rotation units. CAUTION: Propeller must be matched to rotation of drive unit. REMOVAL 1. Lift propeller shaft straight up (about 3 or 4" [7.6 or 10.2cm]) to unseat thrust ring, "0 " ring and load ring. Set propeller shaft back into its normal running position in gear housing and lift the "0 " ring, thrust ring and load ring out of gear housing. 07556 Figure 7. Removing Propeller Shaft 2. To prevent damaging propeller shaft bearing on pinion gear, tilt propeller end of shaft toward anti-cavitation plate while removing shaft from housing. (Figure 7) CLEANING and INSPECTION Tilt Tov«rd Anti-Cavitation Plato 1. Clean assembly in solvent and dry with compressed air. CAUTION: DO NOT spin bearings with compressed air, as bearings may be damaged. 2. Check propeller shaft tapered roller bearings by inspecting bearing cups. Pitting, grooves, scoring, discoloration from overheating, uneven wear and embedded foreign metal particles are all reasons for replacement. Replace both bearing and bearing cup. 3. Inspect propeller shaft where bearing carrier needle bearing rides. (Figure 7) Replace propeller shaft and needle bearing if shaft is pitted, grooved, scored, discolored from overheating, worn uneven or has embedded foreign metal particles. 4. Inspect surface of propeller shaft where bearing carrier oil seal lips contact shaft. (Figure 7) Any groove in shaft in this area requires replacement of shaft and oil seals. 5. Inspect driven gear (right hand rotation) for pitting, chipped or broken teeth and excessive or uneven wear. Replace gear if any of these exist. NOTE: On left hand rotation, pinion gear and drive shaft must be removed before removal of driven gear. 6. Check propeller shaft for straightness: a. Place propeller shaft on balance wheels and spin shaft. Observe shaft for wobble on propeller end of shaft. Replace if bent. b. Place propeller shaft on "V " blocks. Rotate shaft. If propeller end of shaft wobbles, replace shaft. c. Place shaft between centers in lathe. Place dial indicator in area of needle bearing. If total indicator variation is greater than .005" (.127mm) as shaft is revolved, replace shaft. 7. Clean all corrosion from propeller shaft splines. If splines are partially corroded away, replace shaft. Inspect "0 " ring for cuts, nicks, hardness and cracks. If there is any doubt about "0 " rings serviceability, replace HAH * O ring. 9. If gear housing or any internal gear housing components have been changed, a NEW load ring must be used. DISASSEMBLY (Right Hand Rotation) NOTE: For left hand rotation propeller shaft differences refer to "Left Hand Rotation Variations" (see "Index"). 1. Press driven gear and bearing assembly from propeller shaft with Universal Puller Plate Tool (C-91-37241). (Figure 8) Universal Puller Plate (C-91-37241! Figure 8. Removing Propeller Shaft from Driven Gear MERCRUISER DRIVE SYSTEMS -6B-5 Figure 9. Removing Bearing from Driven Gear NOTE: Remove bearing from gear only if replacement is necessary. Using Universal Puller Plate Tool and suitable mandrel, press driven gear bearing from driven gear. (Figure 9) NOTE: Scrap bearing after pressing from driven gear. 3. Press front bearing from propeller shaft with Universal Puller Plate and suitable mandrel. (Figure 10) Bearing Assembly Figure 10. Removing Front Bearing from Shaft DRIVE SHAFT ASSEMBLY and PINION GEAR REMOVAL 1. Reinstall carrier retainer nut to protect threads in housing. Drive Shaft Use Drive Shaft Socket Tool (C-91-63620A1) and remove Puller pinion gear nut and washer. (Figure 1) (C-91-63616! 07551 2. Thread Drive Shaft Puller Tool (C-91-63616) into end of drive shaft. Use Slide Hammer Tool (C-91-34569A1) to separate drive shaft from pinion gear (Figure 2), then remove shaft and gear. Figure 2. Removing Drive Shaft CLEANING and INSPECTION 1. Clean all components in solvent and dry with compressed air. CAUTION: DO NOT spin bearings with compressed air, as bearings may be damaged. 2. Inspect area of drive shaft where roller bearing rides. Pitting, grooves, scoring, uneven wear, discoloration from overheating and embedded foreign metal particles are all reasons for replacement of drive shaft and roller bearing. 3. Check drive shaft upper and lower tapered roller bearings by inspecting bearing cups. Replace bearings and bearing cups if cups are pitted, grooved, scored, worn uneven, discolored from overheating or have foreign metal particles embedded in cup. 4. Inspect drive shaft splines (both ends) for wear. 5. If propeller shaft was bent, check drive shaft for straightness. 6. Inspect drive (pinion) gear for pitting, chipped or broken teeth and excessive or uneven wear. Replace gear if any of above exist. 6B-6 - MERCRUISER DRIVE SYSTEMS 07543 Figure 2. Pressing Upper Bearing from Shaft DISASSEMBLY 1. Press upper bearing from drive shaft with Universal Puller Plate Tool (C-91-37241). (Figure 2) 2. Use Universal Puller Plate to press lower bearing from drive shaft. (Figure 3) TAPERED ROLLER BEARING CUP (DRIVE SHAFT and PROPELLER SHAFT) REMOVAL Using Slide Hammer Tool (C-91-34569AI), remove small drive shaft tapered roller bearing cup from gear housing (Figure 4) and remove shims. Using same procedure, remove propeller shaft tapered roller bearing cup from gear housing and remove shims. CLEANING and INSPECTION Inspect bearing cups for pitting, grooves, scoring, discoloration from overheating, uneven wear and embedded foreign metal particles and replace bearing cup and bearing if any of these exist. Figure 4. Remove Tapered Roller Bearing Cup MERCRUISER DRIVE SYSTEMS - 6A-7 ROLLER BEARING (DRIVE SHAFT) REMOVAL 1. Remove drive shaft pinion roller bearing from gear housing with Driver Rod Tool (C-91-37323) and Mandrel(C-91-55917). (Figure 5) 2. Remove "0 " ring from gear housing oilpassage. CLEANING and INSPECTION Check drive shaft roller bearing by inspecting surface of drive shaft on which bearing rides. If drive shaft bearing surface is grooved, scored, pitted, worn unevenly, discoloredoverheating or has embedded foreign metal particles, bearing and drive shaft must be replaced. Figure 5. Removing Pinion Roller Bearing GEAR HOUSING CLEANING and INSPECTION NOTE: Lower drive shaft (located in gear housing) upper bearing cup should be a loose fit in gear housing. 1. Clean assembly in solvent and dry with compressed air. 2. Check gear housing carefully for impact damage. 4. Inspect bearing carrier retainer threads in gear housing foi 3. Check for loose fitting bearing cups and needle bearings. corrosion or stripped threads. GEAR HOUSING REASSEMBLY - RIGHT HAND ROTATION NOTE: For left hand rotation, follow right hand rotation instructions, following, and refer to "Left Hand Rotation Variations" (see "Index"). IMPORTANT: Install same amount of shims that were removed. Follow "General Service Recommendations" (see "Index"). Refer to Figure B for parts identification. ROLLER BEARING (DRIVE SHAFT) INSTALLATION Tool recirculating from Use Drive Shaft Pinion Bearing Driver Tool (C-91-63638) and Installing Tool (part of C-91-31229A4) to install lower drive shaft pinion bearing with numbered end of bearing case facing up. (Figure 1) Figure 1. Installing Roller Bearing 6B-8 - MERCRUISER DRIVE SYSTEMS INSTALLATION J. Install shims and use Tool C-91-63619 to install small drive shaft bearing cup. (Figure 2) Cup Driver (C-91-63626) Propeller Shaft Front Bearing Cup INSTALLATION J. Install shims and use Tool C-91-63619 to install small drive shaft bearing cup. (Figure 2) Cup Driver (C-91-63626) Propeller Shaft Front Bearing Cup TAPERED ROLLER BEARING CUP (DRIVE SHAFT and PROPELLER SHAFT) Figure 3. Installing Propeller Shaft Bearing Cup 07548 2. Install shims and use Driver C-91-63626 to install front Figure 2. Installing Drive Shaft Bearing Cup propeller shaft bearing cup. (Figure 3) DRIVE SHAFT ASSEMBLY and PINION GEAR REASSEMBLY 1. Install drive shaft and bearing assembly into gear housing. 2. Install pinion gear, dished washer (concave side toward Press lower bearing and upper bearing onto drive shaft with pinion gear) and pinion nut. Use Loctite Type "A " suitable mandrels. (Figure 4) (C-92-32609-1) on pinion nut threads, if shimming is correct. Torque to specifications, using Drive Shaft Socket (C-91-63620A1). Lower Bearing Upper Mandrel 07541 I s^Hli^^HIH Figure 4. Pressing Upper Bearing on Shaft INSTALLATION \0TE: On left hand rotation gear housing, install driven gear before pinion gear and drive shaft. Figure 5. Checking Pinion Gear Shimming SHIMMING (PINION GEAR) a. Carefully place Shimming Tool (C-91-63622) in gear housing. (Figure 5) Push in on drive shaft to simulate bearing preload and rotate to seat bearing MERCRUISER DRIVE SYSTEMS -6B-9 rollers. Hold drive shaft in this position and measure clearance between tool and gear with a feeler gauge. Clearance must be .025. b. If clearance is more or less than .025. remove drive shaft, pinion gear and drive shaft small bearing cup. PROPELLER SHAFT ASSEMBLY REASSEMBLY NOTE: For left hand rotation propeller shaft differences, refer to "Left Hand Rotation Variations" (see "Index"). 1. Use a suitable mandrel and press driven gear bearing onto driven gear. 2. Align driven gear splines with propeller shaft splines and press gear on propeller shaft. Add or remove shims under bearing cup equal to the difference between .025 and your reading. Reinstall bearing cup, drive shaft and pinion gear. Use Loctite Type "A " (C-92-32609-1) on threads of nut. Recheck clearance. RIGHT HAND ROTATION 3. Press front propeller shaft bearing onto propeller shaft with suitable mandrel. INSTALLATION Install assembled propeller shaft into gear housing. Tilt shaft slightly to allow front bearing to clear pinion gear. BEARING CARRIER ASSEMBLY ("O " RING, THRUST RING and LOAD RING) REASSEMBLY 1. Install tapered roller bearing cup in bearing carrier with Driver Tool (C-91-63626). (Figure 6) Driver (C-91-63626) 07540 Figure 6. Installing Bearing Cup Needle Bearing ...MSOW Bearing Adaptor IC-91-55918] I 06229 Figure 7. Installing Needle Bearing 6B-10 - MERCRUISER DRIVE SYSTEMS Figure 8. Installing First Oil Seal Figure 9. Installing Second Oil Seal 2. Using Bearing Adaptor Tool (C-91-55918), install needle bearing in carrier. (Figure 7) 3. Use deep shouldered end of Driver Tool (C-91-55916) to install first oil seal with lip facing in. (Figure 8) Tool (C-91-55916) Deep Shouldered End 4. Use shallow shouldered end of Driver Tool (C-91-55916) to install second oil seal with lip facing out. (Figure 9) 5. Fill space between oil seals with Multipurpose Lubricant (C-92-63250). INSTALLATION NOTE: If gear housing has shims between bearing carrier thrust ring and gear housing shoulder instead of load ring, DO NOT continue with following instructions. Refer to MerCruiser Service Manual C-90-60673 which includes prior models. 1. Install bearing carrier assembly and carrier locating key into gear housing. DO NOT install propeller shaft load ring, thrust ring or "0 " ring at this time. 2. Install threaded bearing carrier retainer WITHOUT tab washer. Torque retainer SLOWLY until sufficient amount of preload is obtained on propeller shaft bearings to check pinion gear backlash. CAUTION: DO NOT over-torque retainer, or damage may occur to propeller shaft bearings. 3. Position dial indicator on machined surface of propeller shaft just behind bearing carrier. Push propeller shaft to one side and hold in this position while zeroing dial indicator. Move propeller shaft to opposite side. Shaft deflection should be max. .003" (,076mm). DO NOT turn propeller shaft. Repeat procedure, moving shaft up-anddown. If shaft deflection is more than .003", shaft and/or needle bearing is worn or propeller shaft is undersize. SHIMMING (GEAR BACKLASH) a. Use Dial Indicator and Indicator Rod (C-91-53459), position Mark II, to check gear backlash which should be .011" to .015" (.279 to .381mm). (Figure 10) Push in on drive shaft to simulate bearing preload and turn drive shaft and pinion gear back-and-forth. Use light turning pressure to prevent propeller shaft from turning. Dial indicator registers amount of gear backlash (clearance) between gear teeth. .on"-.015" 07546 Figure 10. Checking Pinion Gear Backlash b. Right Hand Rotation: If backlash is more than specified, remove shims from under propeller shaft front bearing cup. If backlash is less than specified, add shims under propeller shaft front bearing cup. Left Hand Rotation: If backlash is more than specified, add shims under propeller shaft front bearing cup. If backlash is less than specified, remove shims from under propeller shaft front bearing cup. NOTE: If gear housing or any internal gear housing components have been changed, a NEW load ring must be installed. 4. Remove bearing carrier assembly and install load ring, thrust ring and "0 " ring into gear housing. 5. Coat outer diameters of bearing carrier with Perfect Seal (C-92-34227) and fill space between oil seals with Multipurpose Lubricant (C-92-63250). Reinstall bearing carrier assembly and carrier locating key into gear housing. 6. Install tab washer. Coat threads of retainer with Perfect Seal and install retainer. Torque retainer SLOWLY (periodically checking propeller shaft bearing preload with inch- pound torque wrench, shown in Figure II) until correct propeller shaft bearing preload is obtained. See "Specifications" Section 8. IMPORTANT: DO NOT over-torque retainer to excessive bearing preloads. Over-torque will collapse load ring excessively and require load ring replacement. Figure 11. Checking Propeller Shaft Bearing Preload Torque 7. Bend one tab on bearing carrier retainer tab washer into slot provided on retainer. NOTE: Make a note of propeller shaft bearing preload torque for future use in determining gear housing drive shaft bearing preload torque and drive unit overall bearing preload torque. Adjust gear housing drive shaft bearing preload torque as illustrated in "Gear Housing Installation" (see Index). MERCRUISER DRIVE SYSTEMS - 6B-11 GEAR HOUSING INSTALLATION NOTE: If gear housing, drive shaft housing, lower drive shaft or lower drive shaft components HA VE NOT been replaced, start installation procedures at step No. 5. 1. Set preload on lower drive shaft tapered roller bearings by over-shimming (.060" [.152mm] or more) lower drive shaft bearing cup (located in drive shaft housing). (Figure 12) Connect gear housing to drive shaft housing with 7 nuts. Do not tighten nuts at this time. Figure 12. Over-Shimming Bearing Cup 2. Use preload torque chart (Section 8, "Specifications") and locate drive shaft housing over-all bearing preload torque on top line. Locate propeller shaft bearing preload torque on left side column. (Refer to example shaded area on chart, Section 8, "Specifications") The 2 figures in intersecting block (located on preload chart) are upper and lower limits of drive unit over-all bearing preload torque, as measured from propeller shaft. 3. Tighten gear housing to drive shaft housing nuts evenly to maintain an even gap between housings until bearing preload torque, measured at propeller shaft, is within limits determined from chart. (Figure 13) 4. Measure gap between housings on both sides of drive shaft (Figure 13) and take an average of these readings. Remove gear housing and subtract that amount of shims from under (over-shimmed) bearing cup. then reinstall cup. 5. Install trim tab alien head screw (if removed) in hole provided in gear housing. 6. Install "0 " ring around lower drive shaft bearing cup on drive shaft housing and "0 " ring in groove around oil recirculating passage in gear housing. 7. Connect gear housing to drive shaft housing with 7 nuts. Tighten evenly. Recheck overall preload. 8. Install one alien head screw (located in trim tab cavity). 9. Install trim tab and trim tab screw access hole plug. Replace propeller and propeller components. Figure 13. Installing Gear Housing CAUTION: Propeller nut must be locked with tab washer to retain propeller. 10. Fill drive unit with fresh Super-Dutv Gear Lubricant (C-92-63225 Tube, C-92-63242 Can, C-92-65149 35-lb. pail, C-92-56101 120-lb. drum), as illustrated in "Stern Drive Unit Installation", Section 2. 6B-12 - MERCRUISER DRIVE SYSTEMS DRIVE SHAFT HOUSING ASSEMBLY Figure A. Drive Shaft Housing Parts Identification 47 4 MERCRUISER DRIVE SYSTEMS-6B-13 DRIVE SHAFT HOUSING REMOVAL 1. Remove drive unit from transom as illustrated in "Mer- 2. Separate gear housing from drive shaft housing as outlined Cruiser II-TR, Removing Stem Drive Unit", Section 2. in "Gear Housing Removal" (see "Index"). DRIVE SHAFT HOUSING DISASSEMBLY IMPORTANT: Follow "General Service Recommendations" (see "Index"). BEARING CUP (Lower Drive Shaft), SHIMS, SPACER and COUPLING REMOVAL 1. Mount drive shaft housing in Repair Stand (C-91-33750) with Adaptor (C-91-60524A1). 2. Loosen bearing cup from housing as shown in Figure 1. 3. Remove bearing cup, shims, spacer and drive shaft coupling from housing. (Figure 2) CLEANING and INSPECTION 1. Clean all parts in solvent and dry' with compressed air. 2. Inspect bearing cup for pitting, grooves, scoring, discoloration from overheating, uneven wear and embedded- Figure 2. Removing Bearing Cup, Shims, Spacer and Coupling foreign metal particles. Replace bearing cup and bearing, if any of these exist. 3. Check coupling splines for wear and rust or pitting, if water was present in drive unit. TOP COVER, REAR COVER and "O" RINGS REMOVAL 1. Remove 4 cap screws and remove top cover and "0 " ring. (Figure 3) 2. Remove 4 cap screws and remove rear cover and "0 " ring. Remove guide spring from universal joint shaft. CLEANING and INSPECTION 1. Clean covers in solvent and dry with compressed air. 2. Inspect "0 " ring for cuts, nicks, hardness and cracks. If there is any doubt about "0 " ring serviceability, replace O ring. Figure 3. Removing Top Cover 6A-14 - MERCRUISER DRIVE SYSTEMS 977 R1 07437 Figure 1. Loosen Bearing Cup 4. Replace (with same thickness) all damaged shims. UNIVERSAL JOINT REMOVAL CLEANING and INSPECTION Install Bearing Holder Tool (C-91-63625) in place of rear 1. Inspect splines on both coupling and gear end of universal cover. (DO NOT over-tighten cap screws.) Loosen universal joint assembly for wear. joint shaft nut as shown in Figure 4. Remove nut and universal 2. Clean all corrosion from coupling end. If splines are joint assembly. (Figure 5) partially corroded away, replace coupling end yoke. Figure 5. Removing Universal Joint Shaft NOTE: If universal joint coupling end splines are corroded or worn, also inspect transmission coupling splines. Lubricate universal joint spline and engine coupling splines with Multipurpose Lubricant (C-92-63250) before drive unit installation. 3. Inspect shaft (between yoke and splines) on gear end of universal joint for groove where oil seal rides. If grooved, install NEW oil seal to ride on shaft in new location, using Tool C-91-63619. Refer to "Drive Shaft Housing Reassembly" subhead "Oil Seal (Universal Joint)" (see "Index"). 4. Check bearings for excessive looseness, tightness, roughness and worn or pitted surface from presence of water in bellows. Replace cross and bearing assemblies, if these exist. IMPORTANT: Use only Universal Joint Lubricant (C-92-58229) for lubricating universal joint bearings. Figure 6. Removing Universal Joint Bearing Snap Rings DISASSEMBLY 1. Using a punch and hammer, drive off universal joint bearing snap rings. (Figure 6) 2. Writh suitable adaptor to support universal joint yoke, press on one bearing until opposite bearing is pressed into adaptor. Remove loose bearing. (Figure 7) MERCRUISER DRIVE SYSTEMS - 6A-15 3. Turn universal joint assembly 180° and press on bearing cross-member to remove second bearing. (Figure 8) Remove each pair of bearings in this manner. Figure 7. Removing First Universal Joint Bearing Figure 8. Removing Second Universal Joint Bearing DRIVE GEAR, SHIMS, TAB WASHER and SPACER REMOVAL 1. Remove washer, shims and tab washer. (Figure 9) 2. Remove drive gear and bearing assembly and remove spacer and front bearing. (Figure 10) Figure 10. Removing Drive Gear and Bearing Assembly, Spacer and Front Bearing Figure 9. Removing Washer, Shims and Tab Washer CLEANING and INSPECTION 1. Clean in solvent and dry with compressed air. Inspect drive gear for pitting, chipped or broken teeth and excessive or uneven wear. Replace gear, if any of these exist. 2. Replace (with same thickness) all damaged shims. 3. Check bearing cups for pitting, grooves, scoring, discoloration from overheating, uneven wear and embedded foreign metal particles. Replace bearing cups and bearings, if any of these exist. DISASSEMBLY Using Universal Puller Plate Tool (C-91-37241) and suitable mandrel, press drive gear from bearing. (Figure 11) NOTE: Remove bearing only if replacement is necessary. Bearing is damaged beyond repair during removal. k^ Figure 11. Pressing Gear from Bearing ^m Bearing 6A-16 - MERCRUISER DRIVE SYSTEMS 977 R1 BEARING CUP, OIL SEAL (UNIVERSAL JOINT) and "O" RING REMOVAL 1. Using Slide Hammer Tool (C-91-34569A1), remove universal joint front bearing cup. (Figure 12) Remove shims. Figure 13. Removing Universal Joint Shaft Oil Seal 2. Remove universal joint shaft oil seal with Slide Hammer Tool. (Figure 13) Remove "0 " ring from drive shaft housing pilot. CLEANING and INSPECTION 1. Clean all metal parts in solvent and dry with compressed air. 2. Inspect bearing cup for pitting, grooves, scoring, discoloration from overheating, uneven wear and embedded foreign metal particles. Replace bearing cup and bearing, if any of these exist. 3. Wipe oil seal and "0 " ring with clean rag. 4. Inspect oil seal for wear, tears, roughness and proper spring position. NOTE: If there is a doubt about oil seal or "0" ring serviceability, replace them. Inspect "0 " ring for cuts, nicks, hardness and cracks. DRIVE SHAFT, DRIVEN GEAR, BEARINGS and CHECK VALVE REMOVAL 1. Bend tab washer from upper drive shaft bearing nut. (Figure 14) 2. Using Bearing Nut Wrench (C-91-63620) and Drive Shaft Socket (C-91-63621), loosen upper drive shaft bearing nut. (Figure 15) Turn drive shaft clockwise to loosen nut. 3. Remove nut, tab washer, flat tabbed washer and bearing from bottom of drive shaft housing. Remove driven gear and upper drive shaft assembly from top of drive shaft housing. (Figure 16) 4. Remove driven gear bearing cup and shims with Slide Hammer Tool (C-91-34569A1). (Figure 17) 5. Using Slide Hammer, remove bottom bearing cup. Refer to Figure 17. as procedure is similar. 6. Remove 3 screws, check valve cover, check valve, spring and gasket. 7. Remove quad (sealing) ring from check valve plunger. Figure 14. Bending Tab MERCRUISER DRIVE SYSTEMS - 6A-17 and excessive or uneven wear. Replace gear, if any of these exist. 3. Check bearing cups for pitting, grooves, scoring, discoloration from overheating, uneven wear and embedded foreign metal particles. Replace bearing cups and bearings, if any of these exist. 4. Drive shaft splines should be checked for wear. DISASSEMBLY 1. Press upper drive shaft from driven gear and bearing assembly. (Figure 18) Figure 18. Pressing Shaft from Gear Figure 16. Removing Drive Shaft Assembly and Components CLEANING and INSPECTION 1. Clean all parts in solvent and dry with compressed air. 2. Inspect driven gear for pitting, chipped or broken teeth 07520 Figure 17. Removing Driven Gear Bearing Cup 6A-18 - MERCRUISER DRIVE SYSTEMS Figure 19. Pressing Gear from Bearing 2. Using Universal Puller Plate Tool (C-91-37241) and suitable mandrel, press driven gear from bearing. (Figure 19) NOTE: Remove bearing only if replacement is necessary. Bearing is damaged beyond repair during removal. 977 R1 DRIVE SHAFT HOUSING CLEANING and INSPECTION 2. Check housing carefully for impact damage. 3. Check for loose fitting bearing cups. 1. Clean assembly in solvent and dry with compressed air. DRIVE SHAFT HOUSING REASSEMBLY IMPORTANT: Follow "General Service Recommendations" (see "Index"). Install same amount of shims that were removed. BEARING CUP (for Driven Gear and Drive Shaft) INSTALLATION 1. Install driven gear bearing shims. Use Bearing Cup Driver Tool (C-91 -63626) and install driven gear bearing cup. (Figure 1) 2. Install upper drive shaft bearing cup, as in Step 1, with Cup Driver (C-91-63619). Cup Driver (C-91-63626) Shims 07535 Figure 1. Installing Driven Gear Bearing Cup DRIVE SHAFT and DRIVEN GEAR ASSEMBLY REASSEMBLY 1. Press bearing onto driven gear with suitable mandrel. 2. Press upper drive shaft into driven gear and bearing assembly. INSTALLATION 1. Install assembled upper drive shaft into top of housing. Install drive shaft tapered roller bearing, flat tabbed washer, new tab washer (align tabs on inside diameter of both washers with slot in drive shaft) and bearing nut (chamfered side of nut toward bearing) into bottom of drive shaft housing. (Figure 2) 2. Using Drive Shaft Socket and Wrench (C-91-63620A1), turn drive shaft counterclockwise and tighten nut (Figure 3) a sufficient amount to obtain specified preload (see "Specifications") on upper drive shaft bearings. Check preload as illustrated in Figure 4. Upper Drive Shofr Assembly ^ - 07526 Figure 2. Installing Drive Shaft Assembly and Components NOTE: Make a note of bearing preload torque for future use in determining universal joint shaft bearing preload torque. 278R1 MERCRUISER DRIVE SYSTEMS -6B-19 SHIMMING (DRIVEN GEAR) a. Insert Shimming Tool (C-91-63623) into drive shaft housing with hole marked "MCIITR" toward driven gear. CAUTION: Tool may be damaged if installed improperly. b. Use feeler gauge to measure gap (.025" [.635mm]) between driven gear and shimming tool. (Figure 5) If feeler gauge reading is too low, remove shims from under driven gear bearing cup. If reading is too high, add shims under bearing cup. NOTE: If driven gear bearing cup shims are increased or decreased, upper drive shaft bearings preload torque must be readjusted (as in Step 2, preceding). Align slot on upper drive shaft bearing nut with tab on tab washer and bend tab into slot. OIL SEAL (UNIVERSAL JOINT) INSTALLATION Install universal joint shaft seal in housing with Tool (C-91-63619). (Figure 6) Use side onetime that seal is replaced and side two the second time seal is replaced. NOTE: Seal is factory-installed to be flush with Side one of tool will install seal 1/16" (1.6mm) housing cavity -side two 1/8" (3.2mm) into cavity. If universal joint shaft has been replaced, again should be installed flush with housing. Figure 6. Installing Universal Joint Shaft Oil Seal 6A-20 - MERCRUISER DRIVE SYSTEMS 977 R1 07434 Figure 3. Tightening Bearing Nut Figure 5. Checking Driven Gear Shimming Installation of tool the first housing. into housing oil seal 07536 BEARING CUP (Universal Joint Front Bearing) INSTALLATION Install shims into drive shaft housing. Using flatInstallation Tool (C-91-63619) toward gear (to allow clearance between driven gear and tool), install universal jointtapered roller bearing cup. (Figure 7) Figure 7. Installing Bearing Cup side of shaft DRIVE GEAR ASSEMBLY REASSEMBLY Press bearing onto drive gear with suitable mandrel. INSTALLATION Install bearing, spacer and drive gear and bearing assembly in housing. (Figure 8) Figure 8. Installing Bearing, Spacer and Gear and Bearing Assembly UNIVERSAL JOINT REASSEMBLY 1. Place universal joint bearing caps in yoke and start them on bearing cross-members. Finish installation by pressing IMPORTANT: Use only Universal Joint Lubricant bearings through yoke and onto cross-members. (Figure 9) (C-92-58229) for lubricating universal joint bearings. 2. Install bearing cap retaining snap rings. (Figure 10) 1177R1 MERCRUISER STEERING SYSTEMS - 7B-21 Figure 9. Installing Universal Joint Bearings Figure 10. Installing Bearing Cap Snap Rings INSTALLATION 1. Install tab washer next to bearing cup, with tab in oil hole, and install shims and universal joint shaft washer. (Figure 11) Figure 11. Installing Washers and Shims 2. Install universal joint shaft through front bearing, spacer and drive gear. Install nut on shaft. (Figure 12) 3. Install Bearing Holder Tool (C-91-63625) and torque universal joint shaft nut to specifications. (Figure 13) 4. Install rear cover "0 " ring onto rear cover, then rear cover with 4 cap screws. Torque screws to specifications. 5. Check drive shaft housing over-all bearing preload torque at upper drive shaft. (Figure 4) Preload should be 5 to 11 6C-22 - MERCRUISER DRIVE SYSTEMS 977R1 in. lbs. (.887 to 1.95kg/cm) above preload, measured in "Drive Shaft and Driven Gear Assembly", subhead "Installation". Refer to "Index". Add shims under rear cover to increase preload and remove shims to decrease preloa« Figure 12. Installing Universal Joint 07524 Figure 13. Torque Universal Joint Shaft Nut SHIMMING (DRIVE GEAR) Install Shimming Tool (C-91-63624) into drive shaft housing. Use feeler gauge to measure gap (.025" [.635mm]) between drive gear and shimming tool. (Figure 14) If feeler gauge reading is too low, add shims under universal joint shaft front bearing cup and remove same amount of shims from under rear cover. If reading is too high, remove shims from under front bearing cup and add shims in same amount under rear cover. 07431 Figure 14. Measuring Drive Gear Shimming Figure 15. Installing Bearing Cup, Shims, Spacer and Coupling 9. Install new "0 " ring on drive shaft housing pilot with Bellows Adhesive (C-92-36340). NOTE: If gear housing, drive shaft housing, lower drive 6. Install "0 " ring on top cover. Install top cover with 4 cap shaft or lower drive shaft components have been replaced, screws. Torque to specifications. lower drive shaft bearing preload must be adjusted. 7. Install drive shaft coupler, spacer, shims and bearing cup. Overshim bearing cup .060" (1.524mm) or more and refer (Figure 15) Seat bearing cup in drive shaft housing with to "Gear Housing Installation " (see"Index"). mallet. 8. Install quad (sealing) ring on check valve plunger and install spring, check valve, gasket and cover with 3 screws. 10. Install gear housing as outlined in "Gear Housing Installa- Torque to specifications. tion" (see "Index"). DRIVE SHAFT HOUSING INSTALLATION 1. Install gear housing as outlined in "Gear Housing Installa- ing drive unit. Refer to "II-TR Engine Alignment", Section 2. tion" (see "Index"). 2. Install drive unit as outlined in "II-TR, Stern Drive NOTE: Engine alignment must be checked before install-Installation", Section 2. GIMBAL HOUSING DISASSEMBLY REMOVAL from BOAT NOTE: Remove oil hose at bell housing to drain gear lubricant from reservoir or, when changing bellows or bell Remove gimbal housing and transom plate from boat by housing, plug oil hose to retain gear lubricant in reservoir. referring to - "Removal, Installation and .Alignment", Section 2. BELL HOUSING REMOVAL NOTE: Refer to Section 7, "Trim System", for electrical checks on limit switch and trim sender. 1. Remove trim limit switch and trim position sender assemblies from gimbal ring. 977 R2 MERCRUISER DRIVE SYSTEMS - 6A-23 3. Clean outside diameter of bell housing bellows mounting flanges first with wire brush or sandpaper, then with lacquer thinner. 4. Check bell housing hinge pin threads for damage. Figure 1. Removing Hinge Pin 2. Remove hinge pins with 9/16 alien wrench. (Figure 1) 3. Loosen bellows clamp to remove bellows. (Figure 2) 4. Remove oil hoses and oil check valve (if necessary). CLEANING and INSPECTION 1. Clean parts in solvent and dry with compressed air. DO NOT allow solvent to remain on bellows, or bellows will become unserviceable. 2. Inspect bellows for cracks, cuts, punctures and flexibility. Clean all old adhesive from bellows with lacquer thinner before reinstalling. If there is a doubt about bellows serviceability, replace bellows. Figure 2. Bellows Clamps GIMBAL RING REMOVAL 5. Remove needle bearing and oil seals from gimbal ring with any IVi" O.D. mandrel. 1. Remove cotter pin, to allow removal of lower swivel pin, and remove swivel pin. 2. Remove alien head screws that hold upper swivel pin in position on gimbal ring. (Figures 3 and 4) 06234 Figure 4. Removing Screw from Swivel Pin Elastic Stop Nut Figure 3. Removing Upper Swivel Pin Screw 3. Remove steering arm screw and nut. 4. Loosen swivel pin elastic stop nut (Figure 5) and remove swivel pin part way with Slide Hammer Puller (C-91-34569Al) and Puller (C-91-38919) thru lower swivel pin hole. (Figure 6) Now remove elastic stop nut from swivel pin and remove lower swivel pin from housing. 06231 Gimbal ring now is loose from housing. Figure 5. Removing Steering Arm Elastic Stop Nut 6C-24 - MERCRUISER DRIVE SYSTEMS 977R1 06240 GIMBAL DISASSEMBLY 1. Remove grease fitting from top of gimbal housing (Figure 7) and remove upper needle bearings and seals with long thin drift, if removal is necessary. NOTE that they will be damaged in removal. 2. Remove inhibitor (zinc) plate. 3. Remove hydraulic adaptor and hoses as required. 4. Be sure to inspect exhaust tube "0 " ring and bell housing gasket and replace if necessary. CLEANING and INSPECTION 1. Clean parts in solvent and dry with compressed air. DO NOT allow solvent to remain on oil seals, or seals will become unserviceable. 2. Check needle bearing for serviceability by inspecting bearing contact surface on upper swivel pin. Pitting, grooves, scoring and uneven wear are reason for bearing, swivel pin and oil seal replacement. 3. Inspect oil seals for wear, tears, roughness and proper spring position. If there is a doubt about oil seal serviceability, replace oil seals. 4. Check hydraulic connector for stripped threads. 5. If inhibitor plate is more than Yi eaten away, replace plate. CLEANING and INSPECTION 1. Clean parts in solvent and dry with compressed air. DO NOT allow solvent to remain on oil seals, or seals will become unserviceable. 2. Inspect lower swivel pin where gimbal ring needle bearing rides. If this area of shaft is pitted, grooved, scored, rusty or worn uneven, replace bearing, lower swivel and oil seal. 3. Inspect oil seals for wear, tears and roughness. If there is a doubt about oil seal serviceability, replace oil seals. 4. Check hinge pin bushing (located in gimbal ring) for wear. Figure 6. Removing Upper Swivel Pin HOUSING Figure 7. Removing Needle Bearings 6. Clean outside diameter of gimbal housing bellows mounting flanges first with wire brush or sandpaper, then with lacquer thinner. MERCRUISER DRIVE SYSTEMS -6B-25 GIMBAL HOUSING REASSEMBLY REASSEMBLY 2. Install inhibitor plate. 3. Install hydraulic adaptor and hoses. 4. Install exhaust tube "0 " ring. 1. Press or drive upper needle bearings with upper small and 5. Install grease fitting (located in top of gimbal housing). large oil seals (lips up) into gimbal housing with Driver 6. Lubricate upper needle bearing with Multipurpose Lubri( C-91-55924). cant (C-92-63250). GIMBAL RING REASSEMBLY 1. Press or drive lower needle bearing and lower oil seals (lip up) into gimbal ring with Driver (C-91-55924). 2. Install hinge pin bushings in gimbal ring and epoxv in place with Epoxy Kit (C-92-33673). INSTALLATION 1. Align gimbal ring with gimbal housing and install lower swivel pin and cotter pin. 2. Install upper swivel shaft washers between gimbal ring and housing and under steering arm, placing elastic stop nut over shaft as it is installed. 3. Install steering arm screw and nut, but do not tighten. 4. Install alien head screw (located at upper starboard side of gimbal ring) with Perfect Seal (C-91-34227) and torque to specifications. 5. Install alien head pipe plug (located in bottom of swivel shaft) with Perfect Seal. 6. Tighten elastic stop nut on swivel pin, pulling up on gimbal ring to obtain .005" to .007" (.127 to .178mm) clearance between washer and gimbal ring. (Figure 8) 7. Torque steering arm screw and nut to specifications. Figure 8. Measuring Clearance BELL HOUSING REASSEMBLY WARNING: Extremely flammable! Vapors from Bellows Adhesive may cause flash fire or ignite explosively. Prevent buildup of vapors. Open all windows and doors. Use only in cross-ventilation. Keep away from heat, sparks and open flame. DO NOT SMOKE. Extinguish all flames and pilot lights and turn off stoves, heaters, electric motors and all other sources of ignition during use and until all vapors are gone. Close container after each use. Contains TOLUOL and petroleum distillates. Harmful or fatal if swallowed. Avoid prolonged contact with skin or breathing of vapors. If swallowed, do not induce vomiting. Call physician immediately. Keep out-of-reach of children. 1. Before installing universal joint bellows, clean outside diameter of gimbal housing and bell housing bellows mounting flanges first with a wire brush or sandpaper, then with lacquer thinner. Clean inside diameter of bellows with lacquer thinner. Apply Bellows Adhesive (C-92-36340A1) to inside diameter of each end of bellows. Bellows is marked "Top", "FWD" and "AFT". Use these references when installing bellows. 2. Install bellows with clamps and tighten clamps to specifications. Retighten bellows clamps after 3 to 4 hours. 3. Install exhaust bellows in same manner, without bellows adhesive. 4. Reinstall oil check valve. INSTALLATION 1. Lubricate spacer washers with Multipurpose Lubricant (C-92-63250) and place them over hinge pin bushings. Position bell housing in gimbal ring. 2. Prime clean hinge pin threads in bell housing with Locquic Primer "T " (C-92-59327). Follow instructions on container, then apply Loctite No. 35 (C-92-59328) on threads. Install hinge pins and torque them to specifications. 3. Install oil hose between fittings on valve cover and gimba' housing, tightening hose clamps to specifications. 4. Check universal joint bellows carefully for kinks or uneven folds. 6C-26 - MERCRUISER DRIVE SYSTEMS 977R1 TRIM SWITCH and TRIM SENDER INSTALLATION 1. Thread switch and sender leads into gimbal housing. Install switch lead retainer and tighten screws to 12 ft. lbs. (1.66mkg). Observe position of leads so that they will not interfere with gimbal ring at full starboard turn. Sender leads must point downward 0° to 30°. 2. .Align marks on housing and hex rotor shaft (Figure 1) before installing on gimbal ring. 3. Align shaft with hinge pin hex and push into position. 4. Follow trim limit or trim indicator adjustment, following. 5. Install and tighten adjusting screws. 6. Connect trim sender lead with purple sleeve to purple/ white wire of trim indicator leads. 7. Connect black trim sender lead to black lead of trim indicator leads. Figure 1. Alignment Marks 06094 TRIM LIMIT READJUSTMENT Limiting the drive unit outward trim travel is necessary to ensure safe control at high speeds with certain boats. These boats become difficult to control when the drive is trimmed out too far. Readjustment of the trim limit switch, to restrict the drive's outward travel, will keep it within a safe trimming range. 1. Place drive at maximum desired outward travel (trim) position. 2. Turn stern drive hard to right (starboard). 3. Remove limit switch leads from harness and connect leads to continuity meter. 4. Loosen adjusting screws (Figure 2) which hold trim limit switch. It is normally in the closed circuit position. 5. Rotate switch housing in either direction until switch circuit just opens. 04846 6. Tighten adjusting screws and reconnect switch leads to complete adjustment. TRIM INDICATOR SENDER ADJUSTMENT The following procedure is for fine adjustment of instrument needle to bottom of green arc on instrument face. 1. Turn stern drive hard to left (port) in the full 'Down" trim position. 2. Loosen 2 adjusting screws (Figure 2) which hold Indicator Sender. 3. Turn ignition key to "Run " position. 4. Rotate Indicator Sender housing in either direction (Figure 2) to show indicator instrument needle on bottom of green arc. (Figure 3) 5. Tighten adjusting screws, check instrument reading and turn ignition key to "Off " position. Figure 3. Trim Indicator Instrument 04591 Hex Rotor Shaft Figure 2. Adjusting Trim Limit Switch 1074 MERCRUISER STEERING SYSTEMS - 7B-27 SECTION 6 - DRIVE SYSTEMS PART C-MERCRUISER II-TRS DRIVE UNIT 08487 A BRUNSWICK COMPANY INDEX Page General Service Recommendations 6C-1 Gear Housing Assembly 6C-2 Gear Housing Removal 6C-3 Gear Housing Disassembly 6C-3 Bearing Carrier (Carrier Retainer and Tab Washer) 6C-3 Removal 6C-3 Cleaning and Inspection 6C-4 Disassembly 6C-4 Propeller Shaft Assembly ("O" Ring, Thrust Ring and Load Ring) 6C-4 Left Hand Rotation Variations 6C-4 Removal 6C-5 Cleaning and Inspection 6C-5 Disassembly 6C-5 Drive Shaft Assembly and Pinion Gear 6C-6 Removal 6C-6 Cleaning and Inspection 6C-6 Disassembly 6C-7 Tapered Roller Bearing Cup (Drive Shaft and Propeller Shaft) 6C-7 Removal 6C-7 Cleaning and Inspection 6C-7 Roller Bearing (Drive Shaft) 6C-8 Removal 6C-8 Cleaning and Inspection 6C-8 Gear Housing 6C-8 Cleaning and Inspection 6C-8 Gear Housing Reassembly (Right Hand Rotation) . . . .............. 6C-8 Roller Bearing (Drive Shaft) 6C-8 Installation 6C-8 Tapered Roller Bearing Cup (Drive Shaft and Propeller Shaft) 6C-9 Installation 6C-9 Drive Shaft Assembly and Pinion Gear 6C-9 Reassembly 6C-9 Installation 6C-9 Shimming (Pinion Gear) 6C-9 Propeller Shaft Assembly (Right Hand Rotation) . ........... 6C-10 Reassembly 6C-10 Installation 6C-10 Bearing Carrier Assembly ("0" Ring, Thrust Ring and Load Ring) 6C-10 Reassembly 6C-10 Installation 6C-11 Shimming (Gear Backlash) 6C-11 Gear Housing Installation 6C-12 Drive Shaft Housing 6C-12 Gimbal Housing 6C-12 MERCRUISER n-TRS DRIVE UNIT SERVICE RECOMMENDATIONS Instructions are printed in the sequence which will be followed to assure best results when removing or replacing components. Follow "Disassembly" and "Reassembly" procedures as written. If complete disassembly is not necessary, however, start reassembly at point disassembly was slopped. (Use "Index".) In order to assure correct and durable operation after assembly, it is important that all adjustments and torque value specifications be maintained to the highest degree of accuracy. Use special service tools, where specified, and use common tools of proper fit when removing and replacing parts. When holding housings or parts in a vise - or by other means-use blocks of wood and/or brass shields to prevent marring parts' surfaces. Pressed-on parts (bearings, gears, etc) require adapting appropriate mandrels and supports for the press used. Do not apply force on the bearing cages, mating surfaces or edges which will mar or fail if force is applied. DO NOT spin bearings with compressed air, as bearings may be damaged, and it can be dangerous. To prevent corrosive action, apply Perfect Seal (C-92-34227) to external parts of bearing carrier, bearing carrier retainer and housing mating surfaces during reassembly. DO NOT allow sealer to contact "0 " rings or enter bearings and gears. To ease installation of drive unit components, apply Multipurpose Lubricant (C-92-63250) to the lip of all oil seals and "0 " rings. To prevent oil leakage, apply Loctite Type "A " (C-92-32609-1) on outside diameter of all metal case oil seals. When using Loctite on oil seals or threads, surfaces must be clean and dry. Refer to Section 8, "Specifications", for all torque specifications. Keep a record of shim amounts and location. Be sure to follow shimming instructions closely. Gears must be mounted to correct feeler gauge reading and correct gear backlash to avoid noisy performance and premature failure. Bearing preload must be within specifications, or bearing failure ma\ result. Threaded parts are right hand (RH). unless otherwise indicated. Drive unit should be complete!) disassembled, inspected and cleaned, if either gear housing or drive shaft housing has indicated a failure. A suitable mandrel for pressing tapered roller bearings on shafts and gears can be obtained from the old bearing. Cut outer cage off inner race with hack saw. (Figure A) Remove cage and bearing rollers. Inner race (used as a mandrel) will apply pressing force to inner race of new bearing without damaging bearing cage, rollers or races. Remove bearings from gears or shafts only if replacement is necessary. 977R1 MERCRUISER DRIVE SYSTEMS - 6A-1 GEAR HOUSING ASSEMBLY Figure B. Gear Housing Parts Identification (Right Hand Rotation) 6C-2 - MERCRUISER DRIVE SYSTEMS 574 2.3.4.2.3.4. GEAR HOUSING REMOVAL 1. Remove complete drive unit from bell housing as in "Drive Shaft Housing Removal", Section 2. Drain gear lubricant. Check lubricant for metal particles or water. a. If metal particles are found, disassemble complete drive unit. Clean all parts in solvent (especially bearings) and dry with compressed air. b. If water is found, disassemble complete drive unit. Clean all parts in solvent and dry with compressed air. Apply a light coat of oil to all parts to prevent rusting. Check housings for impact damage and replace all "0 " rings and oil seals. Remove propeller and trim tab. Remove alien head screw located under trim tab. Remove 7 nuts and separate gear housing from drive shaft housing. ^^ Figure 1. Draining Lubricant GEAR HOUSING DISASSEMBLY - RIGHT HAND ROTATION IMPORTANT: Follow "General Service Recommendations" (see "Index"). BEARING CARRIER (CARRIER RETAINER and TAB WASHER) IMPORTANT: Before disassembly, position dial indicator on machined surface of propeller shaft just behind bearing carrier. Push propeller shaft to one side and hold in this position while zeroing dial indicator. Move propeller shaft to opposite side. Shaft deflection should be max .003" (.076mm). DO NOT turn propeller shaft. Repeat procedure, moving shaft up-and-down. If shaft deflection is more than .003", shaft and/or needle bearing is worn, or propeller shaft is undersize. REMOVAL 1. Mount gear housing assembly on Repair Stand (C-91-33750) with Adaptor (C-91-60524Al). 2. Straighten locking tab and loosen threaded retainer with Retainer Tool (C-91-61069 or C-91-53126). (Figure 1) Remove retainer and tab washer. 3. Remove bearing carrier with Slide Hammer (C-9134569A1) and Bearing Carrier Puller (C-91-45086A1). (Figure 2) Be careful not to lose carrier alignment key. Figure 1. Removing Threaded Retainer 977R1 MERCRUISER DRIVE SYSTEMS - 6A-3 2. Check propeller shaft bearing cup for pitting, grooves, scoring, discoloration from overheating, uneven wear and embedded foreign metal particles. Replace bearing cup and bearing if any of these exist. 3. Inspect oil seals for wear, tears, roughness and proper spring position. If there is any doubt about oil seal serviceability, replace oil seals. Inspect surface of propeller shaft where oil seal lips contact shaft. (Figure 3) Any groove in propeller shaft in this area requires oil seals and shaft replacement. 4. Check needle bearing for serviceability by inspecting bearing contact surface on propeller shaft. (Figure 3) Pitting, grooves, scoring, discoloration from overheating, uneven wear and embedded foreign metal particles are reason for bearing and propeller shaft replacement. o. Check threaded retainer for broken or corroded threads and cracks. 6. Replace tab washer. DO NOT re-use. DISASSEMBLY 1. Using Slide Hammer Tool (C-91-34569A1), remove tapered roller bearing cup from bearing carrier. (Figure 4) CLEANING and INSPECTION 1. Clean assembly in solvent and dry with compressed air. DO NOT allow solvent to remain on oil seals, or seals will become unserviceable. !\'0TE: Seals can be removed separately with Slide Hammer (C-91 -34569A 1). Figure 2. Removing Bearing Carrier Figure 3. Propeller Shaft Surface 2. Using Sleeve Tool (C-91-36569) and Driver Rod Tool (C-91-37323), remove needle bearing and 2 oil seals from carrier. (Figure 5) PROPELLER SHAFT ASSEMBLY ("O" RING, THRUST RING and LOAD RING) LEFT HAND ROTATION VARIATIONS bearing have part numbers different than right hand rotation parts. These parts are not interchangeable and are 1. Left hand propeller shaft, front bearing and driven gear assembled differently, as shown in Figure 6. 6C-4 - MERCRUISER DRIVE SYSTEMS 'LoftHond 07539 Figure 6. R.H. and L.H. Propeller Shaft Assemblies 2. Driven gear on left hand rotation is not a press fit to propeller shaft and is installed into gear housing before pinion gear is installed. Propeller shaft then is set into driven gear. 3. Gear shimming and preload are adjusted at same locations for left hand and right hand rotation units. CAUTION: Propeller must be matched to rotation of drive unit. REMOVAL 1. Lift propeller shaft straight up (about 3"or 4" [7.6 or 10.2cm]) to unseat thrust ring, "0 " ring and load ring. Set propeller shaft back into its normal running position in gear housing and lift the "0 " ring, thrust ring and load ring out of gear housing. 07556 Tilt toword Anti-Cavitation Plate Figure 7. Removing Propeller Shaft 2. To prevent damaging propeller shaft bearing on pinion gear, tilt propeller end of shaft toward anti-cavitation plate while removing shaft from housing. (Figure 7) CLEANING and INSPECTION 1. Clean assembly in solvent and dry with compressed air. CAUTION: DO NOT spin bearings with compressed air, as bearings may be damaged. 2. Check propeller shaft tapered roller bearings by inspecting bearing cups. Pitting, grooves, scoring, discoloration from overheating, uneven wear and embedded foreign metal particles are all reasons for replacement. Replace both bearing and bearing cup. 3. Inspect propeller shaft where bearing carrier needle bearing rides. (Figure 7) Replace propeller shaft and needle bearing if shaft is pitted, grooved, scored, discolored from overheating, worn uneven or has embedded foreign metal particlcs. 4. Inspect surface of propeller shaft where bearing carrier oil seal lips contact shaft. (Figure 7) Any groove in shaft in this area requires replacement of shaft and oil seals. 5. Inspect driven gear (right hand rotation) for pitting, chipped or broken teeth and excessive or uneven wear. Replace gear if any of these exist. NOTE: On left hand rotation, pinion gear and drive shaft must be removed before removal of driven gear. 6. Check propeller shaft for straightness: a. Place propeller shaft on balance wheels and spin shaft. Observe shaft for wobble on propeller end of shaft. Replace if bent. b. Place propeller shaft on "V " blocks. Rotate shaft. If propeller end of shaft wobbles, replace shaft. c. Place shaft between centers in lathe. Place dial indicator in area of needle bearing. If total indicator variation is greater than .005" (.127mm) as shaft is revolved, replace shaft. 7. Clean all corrosion from propeller shaft splines. If splines are partially corroded away, replace shaft. 8. Inspect "0 " ring for cuts, nicks, hardness and cracks. If there is anv doubt about "0 " rings serviceability, replace "0 " ring. 9. If gear housing or any internal gear housing components have been changed, a NEW load ring must be used. DISASSEMBLY (Right Hand Rotation) NOTE: For left hand rotation propeller shaft differences refer to "Left Hand Rotation Variations" (see "Index"). 1. Press driven gear and bearing assembly from propeller shaft with Universal Puller Plate Tool (C-91-37241). (Figure 8) Universal Puller Plate (C-91-37241S Figure 8. Removing Propeller Shaft from Driven Gear MERCRUISER DRIVE SYSTEMS - 6C-5 Figure 9. Removing Bearing from Driven Gear NOTE: Remove bearing from gear only if replacement is necessary. 2. Using Universal Puller Plate Tool and suitable mandrel, press driven gear bearing from driven gear. (Figure 9) NOTE: Scrap bearing after pressing from driven gear. Bearing Assembly 3. Press front bearing from propeller shaft with Universal Puller Plate and suitable mandrel. (Figure 10) Bearing Assembly Figure 10. Removing Front Bearing from Shaft DRIVE SHAFT ASSEMBLY and PINION GEAR REMOVAL 1. Reinstall carrier retainer nut to protect threads in housing. Use Drive Shaft Socket Tool (C-91-63620A1) and remove pinion gear nut and washer. (Figure 1) 07551 Figure 1. Removing Pinion Gear Nut 2. Thread Drive Shaft Puller Tool (C-91-63616) into end of drive shaft. Use Slide Hammer Tool (C-91-34569A1) to separate drive shaft from pinion gear (Figure 2), then remove shaft and gear. Drive Shaft Puller (C-91-63616) Figure 2. Removing Drive Shaft CLEANING and INSPECTION 1. Clean all components in solvent and dry with compressed air. CAUTION: DO NOT spin bearings with compressed air, as bearings may be damaged. 2. Inspect area of drive shaft where roller bearing rides. Pitting, grooves, scoring, uneven wear, discoloration from overheating and embedded foreign metal particles are all reasons for replacement of drive shaft and roller bearing. 3. Check drive shaft upper and lower tapered roller bearings by inspecting bearing cups. Replace bearings and bearing cups if cups are pitted, grooved, scored, worn uneven, discolored from overheating or have foreign metal particles embedded in cup. 4. Inspect drive shaft splines (both ends) for wear. 5. If propeller shaft was bent, check drive shaft for straightness. 6. Inspect drive (pinion) gear for pitting, chipped or broken teeth and excessive or uneven wear. Replace gear if any of above exist. 6A-6 • MERCRUISER DRIVE SYSTEMS 1. Press upper bearing from drive shaft with Universal Puller Plate Tool (C-91-37241). (Figure 2) 2. Use Universal Puller Plate to press lower bearing from drive 07542 07543 Figure 2. Pressing Upper Bearing from Shaft DISASSEMBLY 1. Press upper bearing from drive shaft with Universal Puller Plate Tool (C-91-37241). (Figure 2) 2. Use Universal Puller Plate to press lower bearing from drive 07542 07543 Figure 2. Pressing Upper Bearing from Shaft DISASSEMBLY shaft. (Figure 3) Figure 3. Pressing Lower Bearing from Shaft TAPERED ROLLER BEARING CUP (DRIVE SHAFT and PROPELLER SHAFT) REMOVAL Using Slide Hammer Tool (C-91-34569A1), remove small drive shaft tapered roller bearing cup from gear housing (Figure 4) and remove shims. Using same procedure, remove propeller shaft tapered roller bearing cup from gear housing and remove shims. CLEANING and INSPECTION Inspect bearing cups for pitting, grooves, scoring, discoloration from overheating, uneven wear and embedded foreign metal particles and replace bearing cup and bearing if any of these exist. 07550 MERCRUISER DRIVE SYSTEMS -6C-7 ROLLER BEARING (DRIVE SHAFT) REMOVAL 1. Remove drive shaft (pinion) roller bearing fromhousing with Driver Rod Tool (C-91-37323) and Mandrel Tool (C-91-55917). (Figure 5) 2. Remove "0 " ring from gear housing oilpassage. CLEANING and INSPECTION Check drive shaft roller bearing by inspecting surface of drive shaft on which bearing rides. If drive shaft bearing surface is grooved, scored, pitted, worn unevenly, discoloredoverheating or has embedded foreign metal particles, bearing and drive shaft must be replaced. Figure 5. Removing Pinion Roller Bearing GEAR HOUSING CLEANING and INSPECTION NOTE: Loucr drive shaft (located in gear housing) upper bearing cup should be a loose fit in gear housing. 1. Clean assembly in solvent and dry with compressed air. 2. Check gear housing carefully for impact damage. 4. Inspect bearing carrier retainer threads in gear housing for 3. Check for loose fitting bearing cups and needle bearings. corrosion or stripped threads. GEAR HOUSING REASSEMBLY - RIGHT HAND ROTATION NOTE: For left hand rotation, follow right hand rotation instructions, following, and refer to "Left Hand Rotation Variations" (see "Index"). IMPORTANT: Install same amount of shims that were removed. Follow "General Service Recommendations" (see "Index"). Refer to Figure B for parts identification. ROLLER BEARING (DRIVE SHAFT) INSTALLATION Use Drive Shaft (Pinion) Bearing Driver Tool (C-91-55922) and Installing Tool (part of C-91-31229A4) to installdrive shaft pinion bearing with numbered end of bearing case facing up. (Figure 1) Figure 1. Installing Roller Bearing gear recirculating from lower 6C-8 -MERCRUISER DRIVE SYSTEMS TAPERED ROLLER BEARING CUP (DRIVE SHAFT and PROPELLER SHAFT) INSTALLATION 1. Install shims and use Tool C-91-67443 to install small drive shaft bearing cup. (Figure 2) DRIVE SHAFT ASSEMBLY and PINION GEAR REASSEMBLY 1. Install drive shaft and bearing assembly into gear housing. 2. Install pinion gear, dished washer (concave side toward Press lower bearing and upper bearing onto drive shaft with pinion gear) and pinion nut. Use Loctite Type "A " suitable mandrels. (Figure 4) (C-92-32609-1) on pinion nut threads, if shimming is correct. Torque to specifications, using Drive Shaft Socket (C-91-63620A1). Lower Uppei Mandrel Bearing 07541 Figure 4. Pressing Upper Bearing on Shaft INSTALLATION XOTE: On left hand rotation gear housing, install driven gear before pinion gear and drive shaft. 1177R1 MERCRUISER STEERING SYSTEMS - 7B-9 Figure 2. Installing Drive Shaft Bearing Cup Figure 3. Installing Propeller Shaft Bearing Cup 2. Install shims and use Driver C-91-33493 to install front propeller shaft bearing cup. (Figure 3) Figure 5. Checking Pinion Gear Shimming SHIMMING (PINION GEAR) a. Carefully place Shimming Tool (C-91-67441) in gear housing. (Figure 5) Push in on drive shaft to simulate bearing preload and rotate to seat bearing REASSEMBLY NOTE: For left hand rotation propeller shaft differences, refer to "Left Hand Rotation Variations" (see "Index"). 1. Use a suitable mandrel and press driven gear bearing onto driven gear. 2. Align driven gear splines with propeller shaft splines and press gear on propeller shall. BEARING CARRIER ASSEMBLY ("O " RING, THRUST RING and LOAD RING) REASSEMBLY Tool (C-91-31108) Shallow Shouldered 1. Install tapered roller bearing cup in bearing carrier with Driver Tool (C-91-67443). (Figure 6) Figure 8. Installing First Oil Seal Figure 6. Installing Bearing Cup 08625 Needle Bearing Bearing Adaptor (C- 91-37263) 06229 Figure 7. Installing Needle Bearing 6C-10 - MERCRUISER DRIVE SYSTEMS 977R1 rollers. Hold drive shaft in this position and Add or remove shims under bearing cup equal to measure clearance between tool and gear with a the difference between .025 and your reading. feeler gauge. Clearance must be .025. Reinstall bearing cup. drive shaft and pinion gear. b. If clearance is more or less than .025, remove drive Use Loctite Type "A " (C-92-32609-1) on threads shaft, pinion gear and drive shaft small bearing cup. of nut. Recheck clearance. PROPELLER SHAFT ASSEMBLY RIGHT HAND ROTATION 3. Press fronl propeller shaft bearing onto propeller shaft with suitable mandrel. INSTALLATION Install assembled propeller shaft into gear housing. Tilt shaft slightly to allow front bearing to clear pinion gear. 06204 Tool (C-91 -31108! Deep Shouldered End 06205 Figure 9. Installing Second Oil Seal 2. Using Bearing Adaptor Tool (C-91-37263), install needle bearing in carrier. (Figure 7) 3. Use deep shouldered end of Driver Tool (C-91-31108) to install first oil seal with lip facing in. (Figure 8) 4. Use shallow shouldered end of Driver Tool (C-91-31108) to install second oil seal with lip facing out. (Figure 9) 5. Fill space between oil seals with Multipurpose Lubricant (C-92-63250). INSTALLATION 1. Install bearing carrier assembly and carrier locating key into gear housing. DO NOT install propeller shaft load ring, thrust ring or "0 " ring at this time. 2. Install threaded bearing carrier retainer WITHOUT tab washer. Torque retainer SLOWLY until sufficient amount of preload is obtained on propeller shaft bearings to check pinion gear backlash. CAUTION: DO NOT over-torque retainer, or damage may occur to propeller shaft bearings. 3. Position dial indicator on machined surface of propeller shaft just behind bearing carrier. Push propeller shaft to one side and hold in this position while zeroing dial indicator. Move propeller shaft to opposite side. Shaft deflection should be max..003" (,076mm). DO NOT turn propeller shaft. Repeat procedure, moving shaft up-anddown. If shaft deflection is more than .003", shaft and/or needle bearing is wom or propeller shaft is undersize. SHIMMING (GEAR BACKLASH) a. Use Dial Indicator and Indicator Rod (C-91-53459), position Mark III, to check gear backlash which should be .009" to .013" (.229 to .330mm). (Figure 10) Push in on drive shaft to simulate bearing preload and turn drive shaft and pinion gear back-and-forth. Use light turning pressure to prevent propeller shaft from turning. Dial indicator registers amount of gear backlash (clearance) between gear teeth. Figure 10. Checking Pinion Gear Backlash b. Right Hand Rotation: If backlash is more than specified, remove shims from under propeller shaft front bearing cup. If backlash is less than specified, add shims under propeller shaft front bearing cup. Left Hand Rotation: If backlash is more than specified, add shims under propeller shaft front bearing cup. If backlash is less than specified, remove shims from under propeller shaft front bearing cup. NOTE: If gear housing or any internal gear housing components have been changed, a NEW load ring must be installed. 4. Remove bearing carrier assembly and install load ring, thrust ring and "0 " ring into gear housing. 5. Coat outer diameters of bearing carrier with Perfect Seal (C-92-34227) and fill space between oil seals with Multipurpose Lubricant (C-92-63250). Reinstall bearing carrier assembly and carrier locating key into gear housing. 6. Install tab washer. Coat threads of retainer with Perfect Seal and install retainer. Torque retainer SLOWLY (periodically checking propeller shaft bearing preload with inch- pound torque wrench, shown in Figure 11) until correct propeller shaft bearing preload is obtained. See "Specifications" Section 8. IMPORTANT: DO NOT over-torque retainer to excessive bearing preloads. Over-torque will collapse load ring excessively and require load ring replacement. Figure 11. Checking Propeller Shaft Bearing Preload Torque 7. Bend one tab on bearing carrier retainer tab washer into slot provided on retainer. NOTE: Make a note of propeller shaft bearing preload torque for future use in determining gear housing drive shaft bearing preload torque and drive unit over-all bearing preload torque. Adjust gear housing drive shaft bearing preload torque as illustrated in ''Gear Housing Installation" (see Index). MERCRUISER DRIVE SYSTEMS - 6C-11 GEAR HOUSING INSTALLATION DRIVE SHAFT HOUSING For repair instructions on drive shaft housing, refer to "Drive Shaft Housing Assembly", Section 6B - MerCruiser II-TR Drive Unit GIMBAL HOUSING NOTE: If gear housing, drive shaft housing, lower drive shaft or lower drive shaft components HA VE NOT been replaced, start installation procedures at step No. 5. 1. Set preload on lower drive shaft tapered roller bearings by over-shimming (.060" [.152mm] or more) lower drive shaft bearing cup (located in drive shaft housing). (Figure 12) Connect gear housing to drive shaft housing with 7 nuts. Do not tighten nuts at this time. CAUTION: MerCruiser H-TRS drive units with 1.33 to 1 and 1.5 to 1 gear ratios have different preload torque charts (Section 8, "Specifications"). Be sure to use correct chart. 2. Use preload torque chart (Section 8, "Specifications'") and locate drive shaft housing over-all bearing preload torque on top line. Locate propeller shaft bearing preload torque on left side column. (Refer to example shaded area on chart, Section 8, "Specifications") The 2 figures in intersecting block (located on preload chart) are upper and lower limits of drive unit over-all bearing preload torque, as measured from propeller shaft. 3. Tighten gear housing to drive shaft housing nuts evenly to maintain an even gap between housings until bearing preload torque, measured at propeller shaft, is within limits determined from chart. (Figure 13) 4. Measure gap between housings on both sides of drive shaft (Figure 13) and take an average of these readings. Remove gear housing and subtract that amount of shims from under (over-shimmed) bearing cup, then reinstall cup. 5. Install trim tab alien head screw (if removed) in hole provided in gear housing. 6. Install "0 " ring around lower drive shaft bearing cup on drive shaft housing and "0 " ring in groove around oil recirculating passage in gear housing. 7. Connect gear housing to drive shaft housing with 7 nuts. Tighten evenly. Recheck overall preload. 8. Install one alien head screw (located in trim tab cavity). 9. Install trim tab and trim tab screw access hole plug. Replace propeller and propeller components. CAUTION: Propeller nut must be locked with tab washer to retain propeller. 10. Fill drive unit with fresh Super-Duty Gear Lubricant (C-92-75580 tube, C-92-75601 can, C-92-75603 37 lb. pail, C-92-75604 120-lb. drum), as illustrated in "Stern Drive Unit Installation", Section 2. For repair instructions on gimbal housing, refer to "Gimbal Housing", Section 6B - MerCruiser II-TR Drive Unit. 6C-12 - MERCRUISER DRIVE SYSTEMS 977R1 SECTION 6 - DRIVE SYSTEMS PART D - DIRECT DRIVE TRANSMISSION A BRUNSWICK COMPANY INDEX Page Stern Drive Direct Drive Transmission - Series 71 and 72 6D-1 Description 6D-1 Precautions 6D-1 Lubrication Recommendations 6D-1 Procedure for Filling Transmission with Oil . . ............ .6D-1 Procedure for Checking Oil Level 6D-1 Changing Oil 6D-2 Oil Capacity 6D-2 Troubleshooting 6D-2 Removal 6D-4 Disassembly 6D-4 Transmission Case Bushing 6D-9 Output Shaft Bushing 6D-9 Cleaning and Inspection 6D-10 Reassembly 6D-10 Shift Cable Adjustment 6D-17 MerCruiser III Drive Transmission 6D-17 Reverse Lock Valve Adjustment 6D-18 Inboard Transmission 6D-18 Tools 6D-19 All "J" (Special) Tools Listed Herein May Be Purchased from: Kent-Moore, Inc. 28635 Mound Road (Refer to Page 6D-19.) Warr6n' Michi & n 48089 STERN DRIVE DIRECT DRIVE TRANSMISSION SERIES 71 and 72 DESCRIPTION NOTICE: Refer to Last Page in This Part for Special Tools. The transmission consists of a planetary gear set. a forward clutch, a reverse clutch, an oil pump and a pressure regulator and rotary control valve. All are contained in a cast iron housing (along with necessary shafts and connectors) to provide forward, reverse and neutral operation. A direct drive ratio is used for all forward operation. In reverse, speed of the output shaft is equal to input shaft speed, but in the opposite direction. Helical gearing is used to provide operation more quiet than can be obtained with spur gearing. Shifting is accomplished by fore and aft movement of the shift lever. This movement rotates control valve and directs oil under controlled pressure to required channels. Oil pressure is provided by the crescent type pump and drive gear which is keyed to the drive shaft. Pump operates at transmission input speed to provide screened oil to the pressure regulator. From the regulator valve, oil is directed through proper circuits to bushings and anti-friction bearings which require lubrication. A flow of lubricant is present at the required parts whenever the front pump is turning, and it should be noted that supply is positive in forward, neutral and reverse conditions. The unit has seals to prevent escape of oil. Both input and output shafts are coaxial, with input shaft splined for installation of a drive damper, and output shaft splined for connecting to the stern drive unit. PRECAUTIONS 1. Oil cooler must be properly connected to transmission before engine is cranked or started. Failure to properly connect oil cooler will cause forward clutch piston to blow out from over-pressurization. 2. Change oil and clean oil screen once each season. 3. Check oil level at operating temperature. 4. Check oil level immediately after engine is shut off. 5. Use clean containers for handling transmission fluid. 6. Fill transmission prior to starting engine. 7. Use recommended automatic transmission fluids Type "A " Suffix "A " or new Dexron fluid. 8. Flush cooler and cooler lines after a transmission failure and prior to installing a new or rebuilt transmission. 9. Check engine alignment each time a transmission is replaced in boat. 10. Check shift linkage adjustment to insure that transmission shift lever is being positioned so that spring-loaded ball enters chamfered hole inside of shift lever in each selected position. 11. Check oil pressure and temperature when transmission functions indicate that a problem exists. 12. Always check pump hand of rotation prior to assembling transmission to engine to ensure that pump is properly- indexed for engine rotation. 13. Except in emergency, never shift at engine speeds above 1000 RPM. 14. Never remove oil cooler lines or use smaller than recommended 13/32" (10.3mm) diameter cooler lines when operating transmission. 15. Do not permit propeller shaft to rotate when transmission is inoperative. Propeller shaft rotation could be caused by- towing. sailing or operation of second engine which could move the boat through the water and cause propeller to "windmill". 16. Ribbon dope (a thread sealant) must be used on hydraulic connections when hydraulic lines are installed, to prevent hydraulic fluid from leaking. LUBRICATION RECOMMENDATIONS The properties of the oil used in the transmission are extremely important to the proper function of the hydraulic system. Therefore, it is necessary that the recommended oil. automatic transmission fluid (ATF), Type "A", Suffix "A", be used. PROCEDURE for FILLING TRANSMISSION with OIL When filling transmission, add oil until it reaches full mark on dipstick. Quantity of oil depends upon angle of installation, but information to serve as a guide on possible amount needed may be found in chart following. Unit should be turned over 977R1 at engine idle speed for a short time in order to fill all circuits, including cooler and cooler piping. i\OTE: Be sure that cooler is properly installed and that transmission contains oil before cranking or starting engine. PROCEDURE for CHECKING OIL LEVEL Oil level should be checked immediately after stopping engine, and sufficient oil added to again bring transmission oil level to full mark on dipstick assembly. Dipstick assembly need not be threaded into case to determine oil level. Merely insert into case until cap or plug rests on surface surrounding oil filler hole. MERCRUISER DRIVE SYSTEMS - 6A-1 Transmission should be checked periodically to assure proper NOTE: Oil capacity does not include capacity needed for oil level, and oil should be added if necessary. transmission cooler and oil lines, vihich may require an amount greater than in table, below. CHANGING OIL It is recommended that transmission oil be changed once each season. After draining oil from unit, thoroughly clean the removable oil screen before refilling transmission with recommended oil (ATF), Type "A", Suffix "A". 0 I L CAPACITY Transmission Oil Capacity (Quarts) Transmissio TransmissioTransmission nn Mode ModeModel ll 15° Inclined Level 1.8 1.3 AS 1-72C AS 1-71C 1.7 2.1 TROUBLESHOOTING Refer to Section 10, "Troubleshooting". 6D-2 -MERCRUISER DRIVE SYSTEMS 674 71 and 72 SERIES TRANSMISSION (STERN DRIVE) 1 - Transmission Assembly 2 - Bushing Kit 3 - Breather 4 - Spring, poppet 5 - Ball, detent 6 - Dipstick 7 - Spring and Valve Assembly 8 - "O" Ring 9 - Cover, valve 10- Gasket 11 - Screw 12 - Lockwasher 13 - Strainer, oil 14 - Tube, oil strainer 15 - Bushing 16 - Baffle, oil 17 - Gasket 18 - Ring, snap 19 - Washer, thrust 20 - Pinion Gear and Shaft Assembly 21 - Washer, thrust 22 - Key 23 - Drive Gear and Shaft Assembly 24 - Gear, forward clutch 25 - Ring, snap 26 - Key 27 - Ring, sealing 28 - Gear, ring 29 - Plate, pressure 30 - Plate, clutch (outer) bronze 31 - Plate, clutch (inner) steel 32 - Plate, pressure 33 - Spring, clutch plates 34 - Ring, sealing 35 - Ring, forward clutch piston 36 - Piston, forward clutch 37 -"0" Ring 38 - Cylinder, forward clutch 39 - Ball Bearing 40 - Ring, snap - ball bearing retainer 41 • Ring, snap - ball bearing retainer 42 - Washer, thrust 43 - Ring, snap 44 - Plate, reverse clutch 45 - Plate, reverse clutch 46 - Pin, dowel 47 - Spring 48 - Plate, pressure 49 - Ring, sealing 50 - Piston, reverse clutch 51 -"0" Ring 52 - Adaptor 53 - Roller Bearing 54 - Screw 55 - Gasket 56 - Front Pump Assembly 57 - Oil Seal 58 - Screw Figure 1. Transmission, Exploded View 977R1 MERCRUISER DRIVE SYSTEMS - 6A-3 REMOVAL NOTE: Engine must be removed to remove transmission. 2. Remove rear engine mounts from transmission. Re fer to "Removal-Installation-Alignment" Section 2. 3. Remove 6 bolts which attach transmission to flywheel housing. 1. Remove shift linkage and oil lines. 4. Remove transmission. DISASSEMBLY NOTE: Some tools are not available and must be fabricated. Refer to "Tools" at the end of this PART. Tear, down procedure should not begin until transmission exterior and work area have been thoroughly cleaned. 1. Remove oil filler plug, located below shift lever on rear side of transmission case. 2. If space permits, place container with approximately 2 quart capacity' under transmission, located as shown in Figure 2. Unscrew drain plug and cooler return tube assembly. Reach into opening with a suitable tool and remove strainer assembly. (Figure 2) Allow oil to drain into pan. NOTE: Steps 3-thru-6 are for MerCruiser III drive trans mission only. 3. Remove engine coupling guide spring. Being careful not to damage seal lip. lift pump assembly squarely over protruding input shaft. 11. Remove pump assembly and front pump gasket, then remove woodruff key. (Figure 5) 12. Mark pump gears with marking pen to identify proper relocation of gear faces during reassembly. NOTE: Pump and drive gear are a matched set and are not sold separately. 13. To replace oil seal in pump housing, place pump housing squarely on arbor press table. Apply Loctite to outside diameter of seal and press seal into housing with Tool 05386 J-22922 until front face of seal is flush with front face of pump housing. (Figure 6) Wipe away any excess Loctite. 4. Remove 8 cap screws and lockwashers and remove bearing support housing and gasket. 5. Tap shaft to remove shaft and bearing. (Figure 3) 6. Using Snap Ring Pliers (J5586), remove ring retainer, which holds bearing on shaft, and press shaft thru bearing. 7. For inboard transmission with 1:1 gear ratio, remove nut and tap engine coupling assembly with mallet to remove, then remove cover. If transmission has reduction gear assembly attached, remove bolts and remove reduction gear assembly. CAUTION: Remove shift lever carefully; DO NOT lose indent ball and spring. 8. Remove nut, lockwasher and flat washer from shift lever and remove shift lever. 9. Remove 3 screws and lockwashers, valve cover and gasket. Tap out valve assembly. (Figure 4) 10. Note location of arrow on pump. Remove 4 cap screws from oil pump. Apply tape around input shaft splines. 6D-4 - MERCRUISER DRIVE SYSTEMS Figure 2. Draining Transmission Fluid Figure 4. Valve Removal Figure 5. Removing Oil Pump CAUTION: Reverse clutch pressure plate may stick momentarily to reverse clutch piston. To avoid damage, prevent pressure plate from dropping. 14. Remove 4 cap screws (12 point head). (Figure 7) Lift adaptor and reverse clutch piston. (Figure 8) If necessary, tap adaptor with a soft hammer to remove. 15. Force compressed air into reverse clutch cavity while holding piston, as shown in Figure 9, and piston will pop out of reverse clutch cavity. 16. Remove sealing rings as shown in Figures 10 and 11. 17. Check needle bearing in adaptor for wear. Replace if worn. 05394 Tool J-22922 Figure 6. Oil Seal Installation 977R1 Figure 7. Removing Adaptor Oil Adaptor and Holes Reverse Clutch Assembly Pressure Plate Gasket 05331 Figure 8. Removing Adaptor and Reverse Clutch Assembly 18. Remove thrust washer (Item 42 in Figure 1), clutch pressure plate (48), 12 pressure plate springs (47) and 3 dowel pins (46) and reverse clutch pressure plates. (Figure 12) Clutch Piiton Adaptor Figure 9. Disassembling Reverse Clutch Piston MERCRUISER DRIVE SYSTEMS - 6A-5 12 Point Head Cap Screws 19. Grasp exposed front end of input gear and lift straight up. Drive gear and clutch assembly parts easily lift out of opening in front. (Figure 13) 20. Remove thrust washer, located between drive gear and planetary carrier. (Figure 13) 21. Stand drive gear and clutch assembly in suitable fixture and remove internal and external snap rings at ball bearing from drive gear and clutch cylinder (Figure 14), using Snap Ring Pliers (J-5586). Do not permit drive gear to move forward after above snap rings are removed. 22. While holding ring gear, tap front end of drive gear with soft hammer. Drive gear and forward clutch hub assembly will pass thru ring gear and forward clutch assembly to come out of rear end of ring gear. (Figure 15) 23. Remove bearing from clutch cylinder by tapping with soft, blunt tool. 24. Remove ring gear snap ring. (Figure 16) 05294 Figure 10. Removing Sealing Ring Figure 11. Removing Outer Sealing Ring 7B-6 - MERCRUISER STEERING SYSTEMS 1177R1 Figure 12. Removing Reverse Clutch Pressure Plate Figure 13. Removing Drive Gear and Clutch Assembly Figure 14. Removing Snap Ring Ring Gear and Clutch Assembly Drive Gear and Clutch Hub Sealing Assembly Rings Assembly Tool 05315 Figure 15. Removing Ring Gear and Clutch Assembly 25. While holding ring gear, tap with soft, blunt tool on exposed face of forward clutch cylinder inside of ring gear. Forward clutch cylinder will move forward to disassemble out of front of ring gear. After removing clutch spring and clutch spring snap ring, all parts of forward clutch can be disassembled. Arbor Press Assembly Tool Ring Gear Snap Ring • « 05308 Figure 16. Removing and Installing Ring Gear Snap Ring 26. Piston can be removed from forward clutch cylinder (Figure 17) by applying compressed air to clutch cavity- through one of 3 holes in inside diameter of forward clutch cylinder, while other holes are blocked. 27. Remove forward clutch small sealing rings, as shown in Figure 18. 28. Remove forward clutch large sealing ring. (Figure 19) 29. Using Snap Ring Pliers (J-5586). remove snap ring from drive gear. (Figure 20) 977R1 Forward Clutch Piston Forward Clutch Cylinder 05288 Figure 17. Removing and Installing Forward Clutch Piston 30. If drive gear must be replaced, press clutch hub shaft out of drive gear. (Figure 21) 31. Remove pinion cage and output shaft by lifting out of transmission housing. 32. Remove thrust washer from pinion cage and output shaft. 33. Remove oil baffle from transmission housing by pressing down on baffle and pulling baffle out. Sealing Ring Clutch ^ Cylinder 05287 Figure 18. Removing Forward Clutch Cylinder Sealing Ring 05286 Figure 19. Removing Forward Clutch Piston Sealing Ring MERCRUISER DRIVE SYSTEMS - 6A-7 05306 Figure 21. Pressing Clutch Hub Shaft from Drive Gear Figure 20. Removing Clutch Hub Snap Ring 6D-8 • MERCRUISER DRIVE SYSTEMS as oil holes in extra as oil holes in extra TRANSMISSION CASE BUSHING OUTPUT SHAFT BUSHING 1. Check bushings for fit and wear. Replace bushingsrequired. 2. Press bushings from output shaft with Tool C-91-58868. (Figure 3) NOTE: Oil holes in bushings must line up with shaft. (Step 3) 3. Coat inside of bore with Loctite Retaining Compound 35 (C-92-58254A1) and install new bushings from 2 Bushing Kits (B-23-56562) with Tool C-91-58868. Discardbushing. Figure 3. Shaft Bushing Installation 1. Check bushings for fit and wear. Replace bushings as required. 2. Remove bushings with Tools J-8466 and J-7079-2. (Figure 1) 3. Check bore size. Bore should be 1.989" to 1.990". If bore exceeds this dimension, replace housing. 4. Coat inside of bore with Loctite Retaining Compound 35 (C-92-58254A1). Figure 2. Case Bushing Installation Install new bushing from Bushing Kit (B-23-56572) with Tools J-8466 and J-7079-2. Oil holes in bushings must line up with oil holes in case. Bushings are pressed in from their respective ends. 1177R1 MERCRUISER STEERING SYSTEMS - 7B-9 CLEANING and INSPECTION 1. Cleanliness is absolutely necessary during reassembly to 4. Oil seals and bearings are best installed by using an arbok ensure proper functioning of transmission. Transmission press, suitable fixtures and tools to properly align parts case passages always should have pipe plugs removed to being assembled. Using a hammer to position seals and allow for thorough cleaning. bearings can severely damage parts. Use compressed air to dry parts before they are assembled. 5. Use automatic transmission fluid Type "A " Suffix "A " to Do not wipe parts with rags to clean or dry them, as lint lubricate parts as they are assembled. Petroleum jelly may from the cloth may cause erratic valve action. be used on gaskets or other parts that must be held in 2. Inspect all parts for damage or wear. Replace defective position during assembly. .All rubber parts will slide more parts. freely if lubricated. 3. All gaskets, oil seals and rubber sealing rings should be 6. Tighten all bolts and screws evenly to recommended replaced, except in relatively new units. Judgement should torque shown in Section 8. be exercised as to need for replacing parts. REASSEMBLY 1. Place oil baffle inside transmission case with curved portion below cast spherical bosses in case, as shown in Figure 4. 2. Position front end of baffle so that center of baffle rests on top of boss at front center of transmission case, and the turned-down corners of baffle are located below cast spherical bosses at front of transmission case. Snap baffle into position by lifting up on curved portion so that the 2 large holes are located firmly on spherical bosses at rear of transmission case. 3. Support transmission housing with wood support on output shaft end. Install thrust washer with tang in groove of housing. 4. Install pinion cage and output shaft assembly in transmission housing. 5. Place ring gear on a clean surface with external teeth up, as shown in Figure 5. 6. Remove all dirt and solid particles from shoulder inside gear formed by top of internal helical gear. (Figure 5) 7. With smoothly ground face in upward position, install clutch pressure plate (rear) in ring gear as shown in Figure 5. Assembly is complete when clutch pressure plate is firmly and squarely seated on shoulder at bottom of internal splines. Figure 4. Installing Oil Baffle Figure 5. Installing Clutch Pressure Plate (Rear) 8. For Model 71C, lubricate 5 clutch inner plates and 4 outer clutch plates, arrange and assemble as shown in Figure 6. For Model 72C, lubricate 7 clutch inner plates and 6 center clutch plates. Figure 6. Installing Forward Clutch Plates 6D-10 - MERCRUISER DRIVE SYSTEMS Figure 7. Installing Clutch Pressure Plate (Front) 9. Install clutch pressure plate (front) with flat face down in contact with clutch plate, as shown in Figure 7. 10. Install clutch spring snap ring. (Figure 8) Assembly is complete when snap ring is squarely and firmly seated on internal shoulder provided on top of internal splines. CAUTION: Use proper snap ring. Clutch spring snap ring is .090" to .093" (2.29mm to 2.36mm) thick and has a free diameter of 5-19/32" (14.2cm) + 1/16" (1.6mm). 11. With concave side of clutch spring down, install in ring gear as shown in Figure 9. Assembly is complete when clutch spring is seated firmly and squarely on clutch snap ring. 12. Assemble clutch spring bearing ring and a lubricated clutch sealing ring on forward clutch piston as shown in Figure 19 in "Disassembly", preceding. Inspect inside diameter of forward clutch piston which contacts sealing ring. Remove all burrs or scratches and lubricate before assembly. 13. Install a well-lubricated sealing ring in forward clutch cylinder. (Figure 18 in "Disassembly") Lubricate entire forward clutch cylinder before continuing assembly. Figure 8. Installing Clutch Spring Snap Ring 14. After aligning assembled forward clutch piston squarely on assembled forward clutch cylinder, press clutch piston into forward clutch cylinder. (Figure 10) This is a hand assembly and should not require pounding by hammer or pressing on arbor press. Assembly is complete when piston "bottoms" in forward clutch cylinder. 15. Place clutch plate assembly on a suitable support which has been placed on an arbor press. (Figure 11) Center clutch spring in ring gear. 16. Place clutch and shaft assembly into open top of clutch plate assembly. (Figure 11) Place a suitable assembly tool squarely on top of forward clutch cylinder and press down with arbor press until forward clutch cylinder is firmly Clutch Spring \ Snap Ring Figure 9. Installing Clutch Spring Figure 10. Pressing Forward Clutch Cylinder into Ring Gear seated on snap ring, and groove for snap ring is fully- exposed. Check by looking into rear of ring gear to be sure that clutch bearing ring is properly assembled on forward clutch piston. MERCRUISER DRIVE SYSTEMS - 6D-11 17. While maintaining load from arbor press, assemble ring gear snap ring. (Figure 16 in "Disassembly") Tap ring while in place to ensure full seating of ring in groove. CAUTION : Use proper snap ring. Ring gear snap ring is .074" to .078" (1.88mm to 1.98mm) thick and has a free diameter of 5-7/8" (14.9cm) + 1/16" (1.6mm). 18. Place forward clutch hub on a suitable support placed on an arbor press in position shown in Figure 11. Assemble woodruff key in kevway provided on drive gear. (Figure 11) Lubricate outside diameter of drive gear on area which presses into forward clutch hub. Drive Gear Forward Clutch Hub Figure 11. Pressing Drive Gear into Forward Clutch Hub Forward Clutch Hub and Drive Gear Assembly Assembly Tool 05305 Figure 12. Installing Forward Clutch Sealing Rings on Drive Gear 19. Install drive gear and woodruff key squarely into forward clutch hub, being careful to align key with mating keywav in forward clutch hub. (Figure 11) Press drive gear into forward clutch hub until gear "bottoms" on face of forward clutch hub, and groove for snap ring is fully uncovered. 20. Invert forward clutch assembly and install snap ring in groove provided. (Figure 11) Tap ring after assembly with suitable tool to ensure full seating in groove. Figure 13. Assembling Ring Gear and Clutch Assembly on Drive Gear 21. Install 2 forward clutch sealing rings in grooves provided on drive gear. (Figure 12) After installing rings in groove, hook ends and turn rings to ensure freedom of rotation. 22. With drive gear and clutch hub in assembly tool as shown in Figures 11 and 12, place ring gear and forward clutch assembly over drive gear. (Figure 15 in "Disassembly") 23. Lower ring gear and clutch assembly until internal teeth ol clutch plates begin to engage teeth on forward clutch hub. Rotate ring gear to align teeth of plates with teeth on clutch hub. DO NOT force ring gear, or teeth will be damaged. When ring gear and clutch are in correct position, rear end of ring gear should be against assembly tool or "flush" with rear thrust face of drive gear. (Figure 13) DO NOT remove drive gear and clutch assembly from assembly tool or move drive gear forward until Steps 24, 25 and 26 are completed. Any movement of drive gear forward will disengage clutch plates from clutch hub and move sealing rings out of position. Press Assembly Tool Bear Figure 14. Pressing Clutch Bearing In Place 1177R1 7B-12 - MERCRUISER STEERING SYSTEMS Thrust Washer 05296 Figure 15. Installing Thrust Washer 24. Place aligned part« and assembly tool in place on arbor press. Place bearing over protruding drive gear and squarely into bore at front of forward clutch cylinder. Press bearing down with arbor press until bearing is fully seated on shoulder, and snap ring grooves in front of bearing are exposed. (Figure 14) 25. Install external snap ring on drive gear. (Figure 14 in "Disassembly") 26. Using Snap Piing Pliers J-5586, install internal snap ring in clutch cylinder. (Figure 15 in "Disassembly") 27. Place transmission housing on a smooth, clean surface in upright position as indicated in Figure 15. In this position, rear face of rear coupling will provide sufficient base to enable assembly to proceed. 28. Coat drive gear thrust washer with petroleum jelly and assemble into pinion cage and output shaft assembly 05297 Figure 16. Installing Pressure Plate Springs and Dowel Pins (Figure 15) Center washer carefully over bore provided for on rear of drive gear. 29. After lubricating rear end of drive gear and checking centered position of thrust washer, install drive gear and clutch assembly into case and pinion cage and output shaft assembly. (Figure 13 in "Disassembly") Exert care and proper centering at this point to prevent damage to bushings when rear diameter of drive gear enters output shaft. 30. Install 12 pressure plate springs in holes provided in reverse clutch cavity. (Figure 16) Holes should be free from dirt, and all springs should be firmly seated. 31. Coat 3 dowel pins with petroleum jelly and assemble them in 3 grooves provided at outside diameter of reverse clutch cavity. (Figure 16) Assembly is complete when dowel pin is firmly seated on end and into groove, as far as groove contour will permit. 32. Install reverse clutch plates (2 bronze and one steel for 71C Series transmission and 3 bronze and 2 steel for 72C Series) over exposed splined teeth of ring gear. Clutch plate must be firmly and evenly seated on case face which forms rear of reverse clutch cavity. Thrust Figure 17. Installing Thrust Washer and Reverse Clutch Pressure Plate 33. Install reverse clutch pressure plate with 12 holes in down position. Align cast slot in pressure plate with large oil hole in front face of transmission case. (Figure 12 in "Disassembly") Since 12 pressure plate springs are not evenly spaced, slot and oil hole alignment are required to locate pressure plate with relation to pressure plate springs. (Figure 12 in "Disassembly") A properly assembled reverse pressure plate will appear as shown in Figure 17. If pressure plate does not drop down to position, approximately flush with transmission case front face, check 3 dowel pins for possible misalignment. 34. Coat thrust washer with petroleum jellv and assemble. (Figure 17) 35. After checking adaptor for the following, place adaptor on clean surface in position shown in Figure 7 in "Disassembly": a. That needle bearing assembly is clean, properly installed and free from damage. b. That oil passages are free from dirt and obstruction. c. That the reverse clutch cavity outer wall has a smooth, clean surface, free from scratches or burrs and coated generously with petroleum jellv. MERCRUISER DRIVE SYSTEMS - 6D-13 36. Coat sealing ring with petroleum jelly and install in groove of adaptor hub. (Figure 10 in "Disassembly") 37. After lubricating sealing ring with petroleum jelly, assemble in groove of reverse clutch piston as shown in Figure 9 in "Disassembly". 38. Examine inside diameter of reverse clutch piston for smooth, clean surface, free from scratches or burrs and coated generously with petroleum jelly. 39. Place reverse clutch piston on adaptor. (Figure 18) Press down on reverse clutch piston while pulling a smooth, clean screwdriver blade around exposed portion of sealing ring. This will aid chamfered bore in adaptor to compress sealing ring into groove in outside diameter of piston. .Assembly can be completed by using hand pressure until Pull Screwdriver in This Piston Direction Scaling Ring 05290 Figure 18. Installing Reverse Clutch Piston in Adaptor Housing- Driven 05293 Marked for Reassembly Figure 19. Installing Pump Driven Gear piston has "bottomed" in reverse clutch cavity. Exposed face of clutch piston should be flush with adjacent surrounding surface on adaptor when assembly is completed. 40. Coat exposed front of transmission case with petroleum jelly and assemble case and adaptor gasket. (Figure 8 in "Disassembly") 41. Align oil holes as indicated in Figure 8 in "Disassembly", then lower reverse clutch piston and adaptor assembly squarely onto input gear and transmission case. 42. When shoulder on rear of adaptor has entered mating bore in reverse clutch cavity (located in front of transmission Front Pump Gasket Woodruff Key A r-~i j^BK^mmmaBammmm 05300 Figure 20. Installing Pump Drive Gear Key and Front Pump Gasket case) and check of gap between case and adaptor indicates that adaptor is squarely in place, install 4 cap screws. (Figure 7 in "Disassembly") Adaptor now can be pulled down squarely, until contact with case is made, by alternately tightening cap screws a small amount and checking frequently for binding. When adaptor is pulled down as far as possible, tighten 4 screws to 27 to 37 ft. lbs. (3.73 to 5.12mkg) torque. 43. After installing new oil seal, lubricate pump housing with proper transmission oil and place as shown in Figure 19. Install lubricated driven pump gear with identification mark as shown in Figure 20. 44. Lubricate and install pump gasket. (Figure 21) 45. Install woodruff key. (Figure 19) 46. Install pump drive gear on input shaft, with woodruff key- slots in drive gear mating with woodruff key on the input shaft. (Figure 19) NOTE: Assemble the 2 pump gears so that the same gear faces are matched with the machined face of the pump housing as found at disassembly. Marks should have been applied at disassembly to insure proper reassembly. 47. Wrap input shaft spline with tape to protect rubber lip on seal. With pump driven gear properly installed in front pump housing, assemble housing and pump driven gear Figure 21. Installing Pump 7B-14 - MERCRUISER STEERING SYSTEMS 1177R1 LEFT HAND ROTATION Figure 22. Orientation Marks squarely over protruding input shaft. A slight rotation of pump driven gear will allow engagement of pump gear teeth. (Figure 21) 48. Orient pump mounting bolt holes and arrow (indicating direction of rotation) to correspond with direction of rotation required by engine, (Figure 22) If not installed for proper rotation, pump will not produce oil pressure to operate transmission when engine is started. Figure 23. Assembly of Shift Lever 1177R1 05284 Figure 24. Installing Oil Strainer and Cooler Return Tube 49. With pump assembled squarely against adaptor and pump gasket, install 4-5/16-18 hex head bolts. Tighten hex head bolts evenly to torque of 17-22 ft. lbs. (2.35-3.04mkg). Check freedom of rotation of pump gears in pump housing by rotating input shaft. If pump will not rotate freely, disassemble pump and check for foreign material in pump. Any dirt particles on adaptor face will cock pump when mounted on adaptor and cause it to seize. 50. Install "0 " ring on end of control valve. Lubricate "0 " ring with petroleum jelly. 51. Place valve and spring assembly (threaded end first in side of transmission case. (Figure 4 in "Disassembly") 52. To ensure neutral positioning of valve and easier assembly of lever, align .369"-.376" (9.37-9.55mm) width slot in valve with bottom &-20 bolt hole in valve cover face of case. (Figure 4 in "Disassembly") 53. Assemble valve cover gasket, valve cover, lockwashers and hex head bolts. Torque hex head bolts to 8-11 ft. lbs. (1.1-1,5mkg). Figure 25. Installation of Pipe Plugs MERCRUISER STEERING SYSTEMS - 7B-15 Figure 26. Installation of Breather Assembly Figure 26. Installation of Breather Assembly Figure 29. Removing Tail Stock Bearing 54. Coat spring, ball and arm with Quicksilver Anti-Corrosion Oil (C-92-63281). Assemble shift lever and related parts in order shown in Figure 23. Torque hex nut 8-11 ft. lbs. Rotation of valve and spring assembly thru forward, neutral and reverse positions should require no more than fingertip effort. If valve binds in rotation, remove and inspect. 55. Assemble oil strainer assembly, cooler line return bushing and cooler return tube assembly in order shown in Figure 24. Screen end of oil strainer assembly should be approximately 'A" (12.7mm) below face of case when assembly i correctly installed. Tighten cooler line return and oil drain bushing to recommended torque of 25-35 ft. lbs. (3.5^-.8mkg). MerCruiser Tool C-91 - 48630 Figure 30. Installing Tail Stock Bearing Figure 28. Removing Tail Stock Oil Seal 6D-16 - MERCRUISER DRIVE SYSTEMS Mallet 05380 Figure 27. Installing Bearing and Shaft Oil Seal 05387 56. Install dipstick assembly and dry seal plugs (if removed). (Figure 25) 57. If breather assembly was removed, use assembly tool (Figure 26) and install new breather assembly. DO NOT hammer on top of breather assembly. NOTE: Steps 58-thru-66 are for MerCruiser III Drive transmission only. 58. On engine coupling, check welch plug (located in center of coupling) for tightness. If loose, remove welch plug, clean surfaces, coat surfaces with Loctite and drive in new welch plug. Check oil seal. Replace if damaged. 59. Inspect coupling bearing for wear or damage. To replace, remove snap ring and press bearing off coupling. Install bearing on engine coupling. Install snap ring. 60. Install bearing coupler assembly on output shaft spline. Tap coupling with mallet to seat bearing. (Figure 27) SHIFT CABLE MERCRUISER m DRIVE TRANSMISSION 1. Place remote control handle in full forward position. 2. Place transmission in forward gear by moving shift cable lever to the right until detent ball, which is located behind transmission shift lever, is centered in rear hole in transmission shift lever. (Figure 1) 3. Place cable end guide on stud which is located in shift cable lever. (Figure 2) Figure 1. Transmission Shift Lever Position - Forward Gear 4. Adjust brass barrel on shift cable so that barrel can be placed on anchor stud without disturbing shift cable lever position. (Figure 2) 5. Fasten end guide to shift cable lever stud with flat washer and nut. Tighten nut and then back nut off slightly to allow end guide to pivot freely. (Figure 2) 6. Fasten brass barrel to anchor stud with flat washer and nut. Tighten nut securely. (Figure 2) 7. Place remote control handle in full reverse position. 8. Loosen nut which fastens stud to shift cable lever. Move shift cable lever to the left, while sliding stud down slot in 61. If tail stock oil seal and bearing require replacement, remove oil seal with appropriate tool. (Figure 28) Insert tool between bearing and seal and prv out seal. 62. Press bearing out of tail stock with Tool C-91-32325. (Figure 29) 63. Install new bearing with Tool C-91-48630. (Figure 30) 64. Install new oil seal with lips facing inward. Use opposite end of Tool C-91-48630, used previously. 65. Assemble gasket and tail stock housing assembly to transmission, being careful not to damge oil seal. Install 8 cap screws and lockwashers. 66. Install guide spring to engine coupling. 67. For inboard transmission with 1:1 gear ratio, replace oil seal in cover and install cover. Install engine coupling assembly and torque nut to specifications. If transmission has reduction gear assembly, install assembly and torque bolts to specifications. 68. Fill transmission with Type "A " automatic transmission fluid. ADJUSTMENT Figure 2. Shift Cable Installed lever, until detent ball is centered in front hole in transmission shift lever. Tighten nut securely. (Figure 3) 9. Check adjustment by moving remote control handle to full forward. Detent ball must be centered in rear hole in transmission shift lever. (Figure 1) Move control handle to Figure 3. Transmission Shift Lever Position - Reverse Gear MERCRUISER DRIVE SYSTEMS - 6D-17 full reverse position. Detent ball must be centered in front hole in transmission shift lever. (Figure 3) If transmission shift lever is not positioned correctly and does not permit detent ball to be centered in holes, as described previously, readjust cable. REVERSE LOCK VALVE ADJUSTMENT 1. Move remote control handle to full reverse position. 2. Mark, which is located on valve cam lever, and large mark, located on valve cover, must line up as shown in Figure 4. If marks do not line up as shown, loosen nuts "A " and reposition cam lever. Tighten nuts securely after adjustment. Figure 4. Reverse Lock Valve Adjustment INBOARD TRANSMISSION 1. Place remote control lever in neutral gear position. 2. Place transmission shift lever in neutral. Lever is in neutral position when detent is in center hole of shift lever. (Figure 5) 3. Place cable end guide on anchor stud and thread barrel on cable in direction required to place hole in barrel in line with hole which is located in shift lever adaptor. (Figure 5) Figure 5. Shift Cable Installation 4. Fasten barrel to shift lever adaptor with screw, washer and nut. Tighten nut securely. 5. Fasten end guide to anchor stud with washer and nut. Tighten nut securely. 6. Move remote control lever to full forward gear position. 7. Check position of transmission shift lever. If detent is not in rear hole in shift lever, loosen nut on shift lever adaptor stud and slide stud down slot in lever, as required, to place detent in hole. (Figure 5) CAUTION: Detent ball MUST BE positioned in proper hole of shift lever for neutral, forward and reverse position, or transmission will be damaged. 6D-18 - MERCRUISER DRIVE SYSTEMS 674 TOOLS 1. Special Mercury- Marine tools for II-TR transmission repair are included in Kit C-91-65307A1. 2. The assembly tool drawings (shown on this page) are included to illustrate how these tools may be made. Most will provide convenience in assembling and disassembling transmission, but their functions may be performed by substitution of other objects. 3. Special "J " prefix tools can be ordered from Kent-Moore, Inc., 28635 Mound Road, Warren. Michigan 48089. Figure 6. Drawing No. 1 Figure 7. Drawing No. 2 Figure 8. Drawing No. 3 1177R1 MERCRUISER STEERING SYSTEMS - 7B-19 SECTION 6 - DRIVE SYSTEMS PART E - MERCRUISER II-TR and II-TRS TRANSMISSION 08678 A BRUNSWICK COMPANY INDEX Page MerCruiser H-TR and II-TRS Transmission Model A 6E-1 Description 6E-1 Precautions 6E-1 Tools 6E-1 Lubrication Recommendations 6E-1 Procedure for Filling Transmission with Oil . . . . ...............6E-1 Procedure for Checking Oil 6E-1 Changing Oil 6E-2 Troubleshooting 6E-2 Transmission 6E-2 Removal 6E-2 Disassembly and Repair 6E-3 Control Valve Housing Repair 6E-6 Pump Housing and Relief Valve Repair 6E-7 Output Housing Repair and Reassembly 6E-7 Planetary Repair 6E-8 Output Shaft Repair and Reassembly 6E-10 Control Valve Housing Reassembly 6E-11 Pump Housing Relief Valve Reassembly 6E-11 Planetary Reassembly 6E-12 Oil Cooler 6E-12 Transmission Reassembly 6E-13 Installation 6E-15 MERCRUISER II-TR and II-TRS TRANSMISSION MODEL A DESCRIPTION The direct drive transmission consists of a planetary gear set, motor. All, except the shift motor, are contained in aluminum forward multiple disc clutch, reverse band clutch, oil pump, housing and provide forward, reverse and neutral operation, pressure relief valve, rotary control valve and electric shift PRECAUTIONS 1. Change oil once each season. for ease of gauge connection. After test, plug re2. Check oil level at normal engine operating temperature moved from housing can be replaced in elbow.) immediately after engine has been shut off. c. After shifting, and pressure has stabilized, pressure 3. Use clean containers for handling transmission fluid. must not fluctuate more than 5 PSI (.35kg/cm^) when 4. Fill transmission before starting engine. shifting from forward to neutral to reverse. 5. Use only automatic transmission fluid (ATF) Type "A" d. Oil pressure in forward gear at 4000 RPM is 120-145 Suffix "A" or Ford Dextron. PSI (8.44-10.19kg/cm2). 6. If transmission malfunctions, check transmission oil pres-7. Except in emergency, never shift at engine speeds above sure and temperature. Normal pressures and temperatures 1500 RPM. are as follows: 8. Do not permit propeller shaft to rotate for extended periods of time when transmission is inoperative. This a. Oil temperature at normal engine operating tempera-propeller shaft rotation could be caused by towing or ture should not exceed 190° F (88°C). Oil temperature operation of a second engine that causes the propeller to should be measured by removing plug from oil cooler "windmill". An inoperative stern drive should be tilted up (Figure 2 - "Transmission Reassembly") and installing to "trailer" position to prevent "windmilling". suitable temperature gauge. 9. Do not mix types or brands of automatic transmission b. Oil pressure at 750 RPM is 80-105 PSI (5.62-7.38 fluid. kg/cm2). Oil pressure is measured by removing plug 10. Never remove oil cooler hoses or use smaller-thanfrom control valve housing (Figure 4 - "Transmission recommended 3/8" (9.5mm) inside diameter cooler hoses Disassembly and Repair") and installing suitable when operating transmission. pressure gauge. (Elbow C-22-54035 may be installed 11. Check engine alignment each time engine is replaced. TOOLS Special tools, required for transmission repair, are contained in Tool Kit C-91-65307A1. LUBRICATION RECOMMENDATIONS Properties of oil used in the transmission are extremely necessary, add sufficient oil to bring transmission oil level to important for proper function of the hydraulic system; "Full" mark on dipstick. therefore, it is necessary that recommended oil, automatic transmission fluid (ATF) Type "A" Suffix "A" or Ford Dextron, be used. PROCEDURE for FILLING TRANSMISSION with OIL When filling transmission, add oil until level reaches full mark on dipstick. Unit should be shifted several times at engine idle speed to ensure that all oil circuits are filled. CAUTION: Be sure that oil cooler hoses are installed and that transmission contains oil before cranking or starting engine. PROCEDURE for CHECKING OIL Transmission should be checked periodically to assure proper oil level. Check oil level immediately after stopping engine. If Figure 1. Draining Transmission 977R1 MERCRUISER DRIVE SYSTEMS -6E-1 CHANGING OIL 2. Remove drain plug. (Figure 1) 3. After transmission fluid has drained, reinstall drain plug. NOTE: Transmission oil must be changed once each 4- Fill transmission to "Full" mark on dipstick (2 qts. [1.9 season. liters] capacity). 5. Run engine for 2 minutes at idle speed to fill all circuits. 6. Stop engine and check fluid level on dipstick. Add fluid as 1. Place a suitable container under drain location. (Figure 1) required to bring level up to "F " mark on dipstick. TROUBLESHOOTING Refer to Section 10, "Troubleshooting". TRANSMISSION REMOVAL 1. Shift transmission into reverse gear. 2. Remove engine and transmission from boat (refer to Section 2J). Out Figure 1. Shift Cover Removal 3. Remove actuator cover (Figure 1) and shifting leads. (Figure 2) 4. Remove hydraulic hoses from reverse lock valve. Figure 3. Transmission Hose Removal 7. Remove 2 starter motor attaching bolts. 8. Remove 2 flywheel dust cover cap screws. 9. Loosen clamps and remove cooler hoses from transmission cooler. (Figure 3) 10. Remove 6 transmission attaching cap screws and pull transmission straight back and off engine. 11. Install transmission in suitable stand. 12. Remove drain plug and drain oil from transmission. Check oil for metal particles and condensation. (Figure 4) NOTE: All transmission parts should be thoroughly cleaned with solvent. Use compressed air to dry all parts. DO NOT use rags, as lint may cause a transmission malfunction. Figure 2. Harness Bracket and Shift Wire Removal 5. Remove 2 cap screws (Figure 2) and position harness bracket away from transmission. 6. Remove yellow neutral start wire from terminal block on flywheel housing and yellow/black wire from starter solenoid. 07472 Drain Plug Allen Wrench Figure 4. Draining Transmission 6E-2 - MERCRUISER DRIVE SYSTEMS 674 DISASSEMBLY and REPAIR NOTES: a. Use Loctite Hydraulic Sealant on all plugs, cap screws and nuts. Using any other type Loctite may cause transmission failure. b. All transmission parts should be thoroughly cleaned with solvent. Use compressed air to dry all parts. DO NOT use rags, as lint may cause a transmission malfunction. c. All O-rings, seals and teflon seal rings, which are worn or damaged, must be replaced. 1. Remove 7 cap screws from front pump cover (Figure 1), then remove cover and "0 " ring. Use caution when removing cover so that oil seal is not damaged. Mark pump element location with grease pencil. Remove pump inner element (Figure 2) by inserting an alien wrench behind NOTE: Check input pump cover for wear. Pump cover inner element, then pulling. Be careful not to damage inner replacement is not necessary unless cover is deeply pump element. Remove outer element. scratched. Inspect oil seal in cover. Replace parts as necessary. 2. Remove key from input shaft before removing pump housing. Discard key. Remove 7 cap screws and install "T " handles in pump housing. (Figure 3) Pull pump housing straight out. Remove 4 "0 " rings. Figure 3. Pump Housing Removal 07471 Figure 1. Removing Front Cover Motor Figure 4. Reverse Lock Valve Removal Remove cap screws and nuts and remove reverse lock valve if necessary for repair. Remove 4 cap screws, then remove actuating motor and bracket. Remove 2 screws from neutral start switch and remove switch. (Figure 4) 4. Remove control valve housing by removing 7 cap screws and "J" clip. Tap housing with mallet to loosen. Reach under control valve housing and hold with upward force on reverse clutch lever so that the accumulator piston will not fall out. (Figure 5) Remove gasket and "0 " rings. Remove reverse clutch link from reverse clutch band through control valve housing opening. (Figure 5) 6. Remove 6 cap screws, then remove output housing (Figure 6) and "0 " rings. Remove plain washer and "0 " ring from inside of output housing. Note that washer and "0 " ring will be loose inside housing. 7. Remove snap ring from output shaft with Snap Ring Pliers (C-91-24283). (Figure 7) CAUTION: DO NOT drag snap ring across output shaft sealing surface. Figure 2. Removing Pump Elements MERCRUISER DRIVE SYSTEMS -6E-3 Control Valve Housing Reverse Clutch Lever 07458 Figure 5. Control Valve Housing Removal 8. Use suitable tool to press output shaft (Figure 8) until solid resistance is felt. This indicates that inner snap ring has dropped into outer snap ring groove. Move planetary assembly toward output end to remove bearing from housing. (Figure 9) 9. Remove rear output bearing. (Figure 9) Remove inner snap ring with Snap Ring Pliers (C-91-24283). CAUTION: DO NOT drag snap ring across output shaft sealing surface. 10. Remove planetary assembly. 11. Remove reverse band and anchor strut. 12. Remove dipstick. 13. Remove 4 cap screws from oil cooler and remove cooler. (Figure 3 in "Removal") 07457 Figure 6. Output Housing Removal Figure 7. Outer Snap Ring Removal 07463 Figure 8. Pressing Inner Snap Ring into Outer Snap Ring Groove Figure 9. Snap Ring and Bearing Removal 674 MERCRUISER DRIVE SYSTEMS -6E 14. Remove alien head screw, then remove oil pickup assembly and "0 " ring. (Figure 10) IMPORTANT: Lockwasher (located below alien head screw) is a special lockwasher. DO NOT use any other size lockwasher. 15. Remove breather vent and clean. (Figure 7) 16. Loosen locknut and "back out" reverse band adjustment screw several turns. 17. Inspect reverse band adjustment screw seal and replace as necessary. (Figure 4 in "Removal") Figure 10. Oil Pickup Removal 07461 1177R1 MERCRUISER STEERING SYSTEMS - 7B-5 CONTROL VALVE HOUSING REPAIR Accumulator Piston Reverse Clutch Lever 07481 Control Valve Housing Figure 1. Accumulator Piston Removal 1. Pull out accumulator piston. (Figure 1) 2. Press retainer down on press with Piston Housing Compressor and remove snap ring. (Figure 2) 3. Remove retainer, servo spring and servo piston with check valve and spring. Check "0 " ring on servo piston for wear. (Figures 3 and 4) Figure 2. Snap Ring Removal 6E-6 - MERCRUISER DRIVE SYSTEMS 4. Reverse clutch lever may be replaced by removing welch plug, pin and bushing. Servo Spring Figure 3. Servo Spring Removal Servo Piston Check Valve Figure 4. Servo Piston Removal 5. Remove 2 screws and remove control valve cap assembly. (Figure 5) 6. Remove control disc from control valve housing. Reverse Lock Valve Cam Follower Figure 5. Control Valve Cap Removal 07477 7. When center cap screw from control shaft is removed, assembly pulls apart. Check "0 " rings. (Figure 6) 8. Inspect .050" washer on control shaft. Remove roll pin and replace washer, if bent. NOTE: DO NOT remove washer from control shaft unless replacemen t is necessary. Figure 6. Control Valve Disassembly PUMP HOUSING and RELIEF VALVE REPAIR l. Inspect s