Engine Mechanical. Table of Contents. Section 3B - Engine Inspection and Assembly. Engine Inspection and Assembly

Transcription

1 Engine Mechnicl Tle of Contents Section 3B - Generl Specifictions... 3B-2 Engine Specifictions...3B-3 Cylinder Hed... 3B-3 Cylinder Bore... 3B-3 Oil Pump... 3B-3 Piston Bore Clernce...3B-3 Piston Rings...3B-3 Piston Pin...3B-4 Crnkshft... 3B-4 Connecting Rod... 3B-5 Vlve...3B-5 Cmshft... 3B-7 Timing Chin...3B-7 Flywheel...3B-7 Engine Block... 3B-7 Clen nd Inspect...3B-7 Cylinder Reconditioning...3B-8 Cylinder Boring... 3B-8 Cylinder Honing... 3B-9 Piston Selection... 3B-9 Cmshft nd Blnce Shft Berings...3B-10 Engine Block Plugs...3B-13 Oil Filter Bypss Vlve...3B-15 Crnkshft nd Pistons...3B-15 Clening...3B-15 Min Bering Inspection... 3B-15 Crnkshft Instlltion... 3B-16 Min Bering Clernce, Plstic Guge Method... 3B-19 Crnkshft End Ply... 3B-21 Preliminry Inspection... 3B-22 Piston Inspection... 3B-22 Piston Ring Gp Inspection... 3B-24 Assemly... 3B-25 Piston nd Rod Instlltion... 3B-25 Connecting Rod Bering Clernce, Micrometer Method... 3B-29 Connecting Rod Bering Clernce, Plstic Guge Method... 3B-31 Connecting Rod Side Clernce... 3B-32 Oil Pump... 3B-33 Inspection... 3B-33 Ressemly... 3B-34 Instlltion...3B-35 Cmshft nd Blnce Shft... 3B-36 Inspection... 3B-36 Instlltion...3B-37 Timing Chin...3B-40 Inspection... 3B-40 Assemly... 3B-40 Checking Timing Chin Deflection...3B-41 Instlltion...3B-42 Crnkcse Front Cover...3B-42 Instlltion...3B-42 Oil Pn... 3B-43 Inspection... 3B-43 Instlltion...3B-44 Cylinder Hed... 3B-47 Inspection... 3B-47 Repir... 3B-50 Cylinder Hed Ressemly... 3B-53 Instlltion...3B-55 Lifters... 3B-57 Inspection... 3B-57 Lifter Instlltion...3B-58 Rocker Arms nd Pushrods... 3B-59 Inspection... 3B-59 Instlltion...3B-60 Intke Mnifold Assemly... 3B-62 Upper nd Lower Intke Mnifolds... 3B-62 Instlltion...3B-62 Vlve Cover... 3B-64 Instlltion...3B-64 Flywheel...3B-65 Clening nd Inspection... 3B-65 Instlltion...3B-65 Flywheel Housing...3B-67 Clening...3B-67 Inspection... 3B-67 Instlltion...3B-67 Crnkcse Front Cover Oil Sel (Without Removing Front Cover)...3B-67 Removl...3B-67 Instlltion...3B-68 Min Berings, Without Crnkshft Removed... 3B-68 Instlltion...3B-68 Vlves nd Sels (Without Removing Hed)...3B-70 Vlve Spring Assemly Exploded View... 3B-70 Vlve Spring Assemly Removl...3B-70 3 B 90-8M JANUARY 2014 Pge 3B-1

2 Luricnts, Selnts, Adhesives Tue Ref No. Where Used Prt No. 4 9 Loctite 565 PST Expnsion cup plug (cmshft rer ering hole) Otin Loclly Needle Bering Assemly Luricnt Loctite 567 PST Pipe Selnt 66 Loctite 242 Thredlocker Vlve stem locks 8M End of new suction pipe Outside dimeter of engine lock core hole expnsion plug Blnce shft driven ger screw threds Cmshft thrust plte retiner olt threds Intke mnifold olts Premium Ger Luricnt Rocker rm stud threds K Loctite 5900 Ultr Blck RTV Silicone Selnt 136 Luriplte SPO Specil Tools Mercury 25W-40 Synthetic Blend 4-Stroke Engine Oil Cylinder hed side of lower intke mnifold gskets Engine lock t the lower intke mnifold seling surfces Crnkshft front cover sel mting surfce Cmshft loes nd vlve lifters Vlve lifters Blnce shft erings Min erings nd crnkshft ering journls Cylinder wlls Connecting rod erings, pistons, rings, nd cylinder wlls Threds nd mting fces of connecting rod cp nd screws Oil pump components Surfces of oil pump gers nd shfts Blnce shft front ering Cmshft journls Front cover crnkshft sel Crnkshft position sensor O-ring sel Vlve stem Outside surfce of vlve stem ore nd ll surfces of the vlve stem oil sel Surfces nd ends of vlve pushrods Rocker rm nd rocker rm ll contct surfces Ruer seling surfce Upper nd lower ering Otin Loclly 92-8M Piston Ring Expnder Expnds piston rings for removl nd instlltion. Generl Specifictions 6255 Specifiction Bore mm (4.00 in.) Stroke mm (3.480 in.) Firing order Compression rtio 9.4:1 Heds Cst iron Pge 3B M JANUARY 2014

3 Block Rods Crnkshft Pistons Cmshft Upper intke mnifold Lower intke mnifold Specifiction Cst iron (two olt min ering cps) Powder metl Cst iron Cst luminum Steel Aluminum Cst iron Engine Specifictions Cylinder Hed Surfce fltness Cylinder Bore Dimeter Out of round Tper Oil Pump Oil pump dowel pin Piston Bore Clernce Production Service Piston Rings Top Compression Groove clernce Gp At exhust mnifold deck At engine lock deck with n 152 mm (6.0 in.) re At intke mnifold deck Intke mnifold fltness Production Service Production thrust side Production relief side Service Production Service Production Service 0.05 mm ( in.) 0.10 mm ( in.) 0.10 mm ( in.) 0.10 mm ( in.) mm ( in.) mm ( in.) mximum 0.05 mm ( in.) mm ( in.) mximum mm ( in.) mximum mm ( in.) over production Height 6.4 mm ( in.) mm ( in.) mm ( in.) mximum mm ( in.) mm ( in.) mm ( in.) mm ( in.) 90-8M JANUARY 2014 Pge 3B-3

4 Second Compression Groove clernce Gp Oil Control Groove clernce Gp Piston Pin Dimeter Clernce Fit in connecting rod Crnkshft Min Bering Journl Production Service Production Service Production Service Production Service Production Service Limit mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) 0.25 mm (0.010 in.) mximum mm ( in.) interference Numer mm ( in.) Dimeter Numer 2, mm ( in.) Numer mm ( in.) Tper Production mm ( in.) mximum Out of round Production mm ( in.) mximum Service mm ( in.) mximum Min Bering Clernce Production Service Numer 1 Numer 2, 3, 4 Numer 5 Numer 1 Numer 2, 3, 4 Numer mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) Pge 3B M JANUARY 2014

5 Connecting Rod Journl Dimeter Tper Out of round Miscellneous Runout End ply (thrust clernce) Connecting Rod Connecting Rod Bering Clernce Rod side clernce Vlve Clernce (Lsh) Lifter Intke nd exhust Production Service Production Service Production Service Limit mm ( in.) mm ( in.) mximum mm ( in.) mximum mm ( in.) mximum mm ( in.) mximum 0.25 mm (0.010 in.) mximum mm ( in.) mm ( in.) mm ( in.) mm ( in.) Net lsh No djustment Type Hydrulic roller Rocker rm rtio 1.50:1 Vlve lift Intke mm ( in.) Exhust mm ( in.) 90-8M JANUARY 2014 Pge 3B-5

6 Hed nd Stem Vlve dimeter Fce ngle Intke Exhust Intke Exhust mm (1.84 in.) 38.1 mm (1.50 in.) 45 degrees 45 degrees Mrgin fter surfcing Intke 0.79 mm ( in.) minimum Production stem dimeter Intke Exhust mm ( in.) Service stem oversize dimeter Exhust only mm ( in.) Vlve stem oil sel Stem Clernce Instlled height NOTE: Mesured from the top of the vlve guide evel to the ottom of the oil stem sel. 1 2 mm ( in.) Set Production Service Intke Exhust Intke Exhust mm ( in.) mm ( in.) mm ( in.) mm ( in.) Set ngle 46 degrees Top correction cut ngle Intke nd exhust 30 degrees Bottom correction cut ngle 60 degrees Width Intke mm ( in.) Exhust mm ( in.) Runout Intke nd exhust 0.05 mm ( in.) mximum Spring Free length 51.3 mm (2.02 in.) Pressure Vlve closed N (76 84 l) t 43.2 mm ( in.) Vlve open N ( l) t 32.3 mm ( in.) Intke Instlled height Exhust mm ( in.) Approximte numer of coils 4 Pge 3B M JANUARY 2014

7 Cmshft Journl dimeter Journl out of round Cmshft runout Loe lift End ply Timing Chin Chin deflection Flywheel Runout Intke Exhust mm ( in.) mm ( in.) mximum mm ( in.) mximum mm ( in.) mm ( in.) mm ( in.) 11 mm ( in.) mximum mm ( in.) mximum Engine Block Clen nd Inspect 1. Clen the engine lock with clening solvent. 2. Flush the engine lock with clen wter or stem. 3. Clen the cylinder ores. 4. Clen the oil glleries nd the oil pssges. 5. Clen the scle nd the deposits from the coolnt pssges. NOTE: Clen ll deris, dirt, nd coolnt from the engine lock cylinder hed olt holes. Filure to remove ll foreign mteril my result in dmged threds, improperly tightened fsteners, or dmge to the components. 6. Clen the engine lock cylinder hed olt holes. 7. After clening the engine lock, spry or wipe the cylinder ores nd the mchined surfces with clen engine oil. 8. Inspect the following res: 90-8M JANUARY 2014 Pge 3B-7

8 . Coolnt jckets for crcks. c d - Coolnt jckets - Cylinder ores c - Vlve lifter ores d - Threded holes e - Crnkshft ering wes f - Crnkshft ering cps g - Crnkshft ering ores h - Core hole plug ores i - Engine lock j - Engine mount osses d d e f g j i h Cylinder ores for scrtches or gouging. c. Vlve lifter ores for excessive scoring or wer. d. Threded holes for dmge. e. Crnkshft ering wes for crcks. f. Crnkshft ering cps nd the crnkshft ering ores for dmge. g. Engine lock core hole plug ores for dmge. h. Engine lock for crcks or dmge. i. Engine mount osses for dmge. Cylinder Reconditioning NOTE: The effectiveness of cylinder reconditioning depends upon engine condition t time of repir. NOTE: If engine lock inspection indictes tht the lock is suitle for continued service, out of round, or tpered cylinders cn e reconditioned y honing or oring nd honing. 1. If cylinders hve less thn mm (0.005 in.) wer, they cn e reconditioned with hone nd fitted with high limit stndrd size pistons. If there is more thn mm (0.005 in.) wer, ore nd hone to fit the smllest oversized piston tht will permit the complete resurfcing of ll cylinders. 2. Clen cylinder ores with hot sopy wter. Rinse thoroughly. After clening, lightly luricte the cylinder wlls with engine oil nd clen cloth. Wipe off excess oil with clen dry cloth. Cylinder Boring IMPORTANT: Before using ny type of oring r, file the top of the engine lock to remove dirt or urrs. This prevents oring r tilt (the ored cylinder wll is not t right ngles to the crnkshft). 1. File the top of the engine lock to smooth ny irregulr surfce nd remove ny deposits or urrs. Pge 3B M JANUARY 2014

9 2. Clen the cylinders with wrm wter nd detergent. Rinse thoroughly. 3. Mesure the piston to e fitted with micrometer. Tke mesurements t the center of the piston skirt nd t right ngles to the piston pin. NOTE: Hone cylinders s outlined under Cylinder Honing nd Piston Selection. 4. Bore the cylinder to the sme dimeter s the piston nd hone to provide the specified clernce. 5. Crefully oserve equipment mnufcturer's instructions. Cylinder Honing 1. Follow the instructions provided with the cylinder hone kit. Prt Numer Kent Moore cylinder hone tool kit J Frequently clen the cylinder ore nd check the piston for correct fit in the cylinder. 3. When finish honing cylinder ore to fit piston, move hone up nd down t sufficient speed to otin very fine uniform surfce finish mrks in 30 degree cross htch pttern. Finish mrks should e clen ut not shrp, free from emedded prticles, nd torn or folded metl. 4. As ech piston is fitted to cylinder, permnently mrk ech with its corresponding cylinder numer. IMPORTANT: Hndle pistons with cre nd do not ttempt to force them into cylinder until it is honed to the correct size. 5. Thoroughly clen cylinder ores with hot sopy wter. Scru ech cylinder with stiff, synthetic ristle rush, nd rinse thoroughly with hot wter. Lightly luricte the cylinders with light engine oil on clen cloth, then wipe clen with clen dry cloth. Repet this process severl times until the oiled cloth remins clen nd free of mchining deris. The cylinder should not e clened with kerosene or gsoline. Clen the engine lock to remove dirt nd deris left y the reconditioning process. Piston Selection 1. Check used piston to cylinder ore clernce:. Mesure the cylinder ore dimeter with telescope guge 64 mm (2.5 in.) from the top of the cylinder ore. Mesuring cylinder ore dimeter. Mesure the piston dimeter t the skirt 11 mm ( in.) from the ottom of the skirt t right ngle to the piston pin ore Piston dimeter - Mesurement loction c. Sutrct the piston dimeter from the cylinder ore dimeter to determine piston to ore clernce. d. Determine if the piston to ore clernce is in n cceptle rnge. 90-8M JANUARY 2014 Pge 3B-9

10 Production Service mm ( in.) mm ( in.) mximum 2. If used piston is not stisfctory, determine if new piston cn e selected to fit the cylinder ore within the specified rnge. 3. If the cylinder ore must e reconditioned, mesure the new piston dimeter, then hone the cylinder ore to the correct clernce. 4. Mrk ech piston to identify the cylinder for which it ws fitted. Cmshft nd Blnce Shft Berings Cmshft Bering Instlltion IMPORTANT: When instlling the cmshft erings, lwys look in order to ensure tht the cmshft ering luriction hole is locted ove the 3 o clock position or the 9 o clock position. The proper positioning of the cmshft ering luriction hole is in order to ensure the est luriction of the engine cmshft journls. - 3 o clock position - 9 o clock position Select the hndle (10), the expnding driver (4 8), the wsher (2 or 3), nd the expnder ssemly (15) from the J Assemle the J Cone 2 - Wsher 3 - Wsher 4 - Expnding driver 5 - Expnding driver 6 - Expnding driver 7 - Expnding driver 8 - Expnding driver 9 - Hndle extension 10 - Hndle 11 - Bushings 12 - Spcer 13 - Spcer 14 - Pin 15 - Expnder ssemly Cmshft ering service kit Prt Numer J33049 Pge 3B M JANUARY 2014

11 IMPORTANT: The cmshft erings vry in size. When ordering the new cmshft erings, e sure to order the correct cmshft erings for the ppliction to e serviced. Alwys instll the cmshft outer erings #1 nd #4 first. The cmshft outer erings serve s guide for the J33049 nd help center the cmshft inner erings during the instlltion process. - Cmshft ering service kit driver (J33049) 3. Instll the new cmshft outer erings #4 nd #1.. Instll the new cmshft outer ering #4 onto the J33049 expnder ssemly.. Tighten the J33049 expnder ssemly nut until snug. c. Align the luriction hole of the cmshft outer ering #4 ove the 3 o clock position or the 9 o clock position of the cmshft outer ering ore #4 t the rer of the engine lock. d. Drive the cmshft outer ering #4 into the cmshft outer ering ore #4 t the rer of the engine lock. e. Loosen the J33049 expnder ssemly nut. f. Remove the cmshft outer ering #4 from the J33049 expnder ssemly. g. Instll the new cmshft outer ering #1 onto the J33049 expnder ssemly. h. Tighten the J33049 expnder ssemly nut until snug. i. Align the luriction hole of the cmshft outer ering #1 ove the 3 o clock position or the 9 o clock position of the cmshft outer ering ore #1 t the front of the engine lock. j. Drive the cmshft outer ering #1 into the cmshft outer ering ore #1 t the front of the engine lock. k. Loosen the J33049 expnder ssemly nut. l. Crefully slide the J33049 into the engine lock until the J33049 expnder ssemly is positioned etween the cmshft inner ering ores. 4. Instll the cmshft inner erings #3 nd # Cmshft ering tool ssemled (J33049) Instll the new cmshft inner ering #3 onto the J33049 expnder ssemly.. Tighten the J33049 expnder ssemly nut until snug. c. Align the luriction hole of the cmshft inner ering #3 ove the 3 o clock position or the 9 o clock position of the cmshft inner ering ore #3 of the engine lock. d. Push the J33049 guide cone into the cmshft front ering ore #1 in order to lign the J e. Drive the cmshft inner ering #3 into the cmshft inner ering ore #3 of the engine lock. 90-8M JANUARY 2014 Pge 3B-11

12 f. Loosen the J33049 expnder ssemly nut. g. Crefully slide the J33049 until the J33049 expnder ssemly is positioned etween the cmshft inner ering ore #2 nd the cmshft outer ering ore #1. h. Instll the new cmshft inner ering #2 onto the J33049 expnder ssemly. i. Tighten the J33049 expnder ssemly nut until snug. j. Align the luriction hole of the cmshft inner ering #2 ove the 3 o clock position or the 9 o clock position of the cmshft inner ering ore #2 of the engine lock. k. Push the J33049 guide cone into the cmshft front ering ore #1 in order to lign the J l. Drive the cmshft inner ering #2 into the cmshft inner ering ore #2 of the engine lock. m. Loosen the J33049 expnder ssemly nut. 5. Crefully remove the J33049 from the engine lock. 6. Cot the outer dimeter of new cmshft rer ering hole expnsion cup plug with selnt. 7. Instll new cmshft rer ering hole expnsion plug. IMPORTANT: The cmshft rer ering hole plug must e instlled 8.8 mm (0.35 in.) deep nd must e prllel with the rer surfce of the engine lock. - Cmshft rer ering hole expnsion cup plug - Mesurement 8.8 mm (0.35 in.) Tue Ref No. Where Used Prt No. Loctite 565 PST Expnsion cup plug (cmshft rer ering hole) Otin Loclly Blnce Shft Bering Instlltion 1. Instll J from the lnce shft service kit (J38834) onto the short threded end of the rod (J ). Blnce shft service kit Prt Numer J Instll the nut, the wsher, nd the ering from the lnce shft service kit (J38834) onto the long threded end of the rod (J ). 3. Instll J from the lnce shft service kit (J38834) onto the rod (J ) so tht the smller dimeter of J will e fcing the front of the engine lock. 4. Instll J on the inside of the lnce shft front ering ore. 5. Luricte the new lnce shft rer ering. Tue Ref No. Where Used Prt No. 139 Mercury 25W-40 Synthetic Blend 4-Stroke Engine Oil 6. Instll the lnce shft rer ering onto J Blnce shft erings 92-8M Pge 3B M JANUARY 2014

13 7. Align the ering for instlltion. 8. Using wrench, secure the rod (J ). 9. Rotte the nut until the lnce shft ering is completely pushed into the lnce shft rer ering ore. c - Blnce shft service kit (J ) - Rod (J ) c - Blnce shft service kit (J ) Remove the tool. Engine Block Plugs Instlltion! CAUTION Wer eye protection when performing the following procedure. Filure to do so my cuse personl injury. 1. Apply Loctite 242 Thredlocker selnt to the outside dimeter of ech new engine lock core hole expnsion plugs. 2. Instll the engine lock core hole expnsion plugs flush with the inside chmfer of the engine lock core hole. - Inside chmfer - Core hole Tue Ref No. Where Used Prt No. 66 Loctite 242 Thredlocker Outside dimeter of engine lock core hole expnsion plug Apply selnt to the threds of the oil pressure sender nd oil gllery plugs. 90-8M JANUARY 2014 Pge 3B-13

14 4. Instll the oil pressure sender nd oil gllery plugs indicted. Tighten the oil gllery plugs to the specified torque. - Left rer top oil gllery plug - Rer oil gllery plugs c - Oil pressure sender loction c Tue Ref No. Where Used Prt No. Loctite 565 PST Threds of oil gllery plugs nd oil pressure sender Otin Loclly Nm l in. l ft Oil gllery plug Cot the threds of the new engine lock oil gllery plugs. Tue Ref No. Where Used Prt No. Loctite 565 PST Threds of the oil gllery plug Otin Loclly 6. Instll the front oil gllery plugs recessed into the engine lock front surfce s indicted. - Engine lock front surfce - Front oil gllery plugs c - Mesurement 0.11 mm (0.004 in.) c Cot the threds of the engine lock coolnt drin hole plugs. Tue Ref No. Where Used Prt No. Loctite 565 PST Threds of the engine lock coolnt drin hole plug Otin Loclly 8. Instll the engine lock coolnt drin hole plugs. Tighten the plugs to the specified torque. Nm l in. l ft Engine lock coolnt drin hole plug Pge 3B M JANUARY 2014

15 Oil Filter Bypss Vlve 1. Instll new oil filter ypss vlve. - Oil filter ypss vlve 2. Instll the oil filter ypss vlve into the oil gllery ore until slightly elow flush with the surfce of the engine lock. 3. Using pointed punch, stke the engine lock re round the oil filter ypss vlve. Stke in three loctions 120 prt. Crnkshft nd Pistons Clening 1. Connecting rods. Clen the connecting rods in clening solvent.. Dry prts with compressed ir. 2. Connecting rod erings. Clen the connecting rod erings in clening solvent. Do not scrtch the ering contct surfces.. Wipe the erings clen with soft cloth. c. Dry prts with compressed ir. 3. Pistons. Clen the pistons in clening solvent.. Clen vrnish from the piston skirt nd pin with suitle clening solvent. c. Clen the piston ring grooves. d. Clen the piston oil luriction holes nd slots. e. Dry prts with compressed ir. 4. Piston pin. Clen the prts in clening solvent.. Dry the prts with compressed ir. Min Bering Inspection This MerCruiser engine uses precision insert type min erings. If the instlled ering clernce exceeds specifiction then the ering ssemly must e replced. Service erings re ville in stndrd size nd mm (0.001 in.), mm (0.010 in.), nd mm (0.020 in.) undersized. Selective fitting of oth rod nd min ering inserts is necessry in production to otin close tolernces. For this reson you my find 1/2 of stndrd insert with 1/2 of mm (0.001 in.) undersized insert, which will decrese the clernce mm ( in.) over using complete stndrd size ering set. When production crnkshft cnnot e precision fitted y this method, it is then ground mm (0.009 in.) undersized, on only those min journls tht cnnot e properly fitted. All journls will not necessrily e ground undersized. A mm (0.009 in.) undersized ering nd mm (0.010 in.) undersized ering my e used for precision fitting in the sme mnner s previously descried. 90-8M JANUARY 2014 Pge 3B-15

16 Due to loding fctors, the lower hlf of crnkshft ering set will generlly exhiit the most wer. If inspection indictes the lower ering hlf is suitle for reuse, it cn e ssumed tht the upper ering hlf cn lso e reused. If the lower ering hlf shows evidence of wer or dmge, replce the entire ering set. Never replce one hlf of ering set without replcing the other hlf. c Min ering filure exmple - Contmintion scrtches - Contmintion prticles c - Tpered journl d - Oil strvtion e - Rdius ride f - Improper seting g - Ftigue filure d e Crnkshft Instlltion f Min Bering Tension IMPORTANT: Ensure tht the min ering is instlled under tension. It should require firm pressure to fit the ering into position. g Min Berings nd Crnkshft Min ering tension 1. Remove the timing sprocket from the old crnkshft nd instll on the new crnkshft. 2. On the driveshft extension models If the old pilot ushing is to e reused, the ushing cn e removed without dmge s follows:. Fill the pilot ushing cvity with grese. Pge 3B M JANUARY 2014

17 . Insert n old trnsmission input shft in the ore of the ushing nd hit it with hmmer. This will crete hydrulic pressure in the pilot ushing cvity tht should force the ushing out. IMPORTANT: Ensure tht ll erings nd crnkshft journls re clen. 3. Instll the upper min ering inserts in the engine lock. - Upper insert - Oil groove Instll the lower min ering insert into the min ering cps. - Lower insert - Min ering cp M JANUARY 2014 Pge 3B-17

18 5. Crefully lower the crnkshft into plce. Be creful not to dmge the ering surfces Instll the min ering cps in the originl loction with the mrkings pointing towrd the front of the engine Check the clernce of ech min ering, following the procedure outlined under Min Bering Clernce, Plstic Guge Method. 8. When ering clernces meet specifictions, luricte the min erings nd crnkshft ering journls. Tue Ref No. Where Used Prt No. 139 Mercury 25W-40 Synthetic Blend 4-Stroke Engine Oil Min erings nd crnkshft ering journls 92-8M Pge 3B M JANUARY 2014

19 9. Instll the min ering cps Check min ering clernce using Plstiguge. Refer to Min Bering Clernce, Plstic Guge Method. 11. Tighten ll min ering cps, except the rer min cp, to the specified torque. Nm l in. l ft Crnkshft min ering cp olt nd stud preferred method First Finl +73 Nm l in. l ft Crnkshft min ering cp olt nd stud optionl method Tighten the rer min ering cp. Using one of the following methods: Preferred method:. Do the first step torque on the rer min ering cp. Nm l in. l ft Crnkshft (min) ering cp olt nd stud preferred method First Using led hmmer, tp the end of the crnkshft to the rer. c. Using led hmmer, tp the end of the crnkshft to the front. d. Do the finl step torque on the ering cp. Nm l in. l ft Crnkshft (min) ering cp olt nd stud preferred method Optionl method: Finl +73. Tp the end of the crnkshft to the rer nd then to the front with led hmmer.. Evenly tighten the rer min ering cp to the specified torque. Nm l in. l ft Crnkshft (min) ering cp olt nd stud optionl method Check the crnkshft end ply. 14. Instll the rer min sel retiner nd sel. 15. Check the clernce for ech connecting rod ering. Refer to Connecting Rod Bering Clernce, Micrometer Method or Connecting Rod Bering Clernce, Plstic Guge Method. Min Bering Clernce, Plstic Guge Method To otin ccurte mesurements while using Plstiguge or its equivlent, the engine must e out of the ot nd upside down so the crnkshft will rest on the upper erings nd the totl clernce cn e mesured etween the lower ering nd journl. 90-8M JANUARY 2014 Pge 3B-19

20 To ensure the proper seting of the crnkshft, ll ering cp olts should e t specified torque. In ddition, the surfce of the crnkshft journl nd ering must e wiped clen of oil. NOTE: When checking the numer 1 min ering, loosen the ccessory drive elt to prevent otining tpered reding with the guging plstic. 1. Remove the ering cp nd wipe ny oil from the journl nd ering cp to e inspected. 2. Plce piece of guging plstic the full width of the ering nd prllel to the crnkshft centerline s shown. Min ering plstic guge mesurement - Guging plstic - Bering journl IMPORTANT: The ering cps must e tightened to the specified torque to ensure correct mesurements. Do not rotte the crnkshft with the plstic guge instlled. 3. Instll the ering cp nd evenly tighten the min ering cp olt or stud to the specified torque. Nm l in. l ft Crnkshft min ering cp olt nd stud, preferred method First Finl + 73 Nm l in. l ft Crnkshft min ering cp olt nd stud, optionl method Remove the ering cp. The flttened guging plstic will e found dhering to either the ering cp or the journl. 5. On the edge of the guging plstic envelope there is grduted scle tht is correlted in thousndths of n inch. Without removing the guging plstic from the crnkshft ering or journl, mesure its compressed width t the widest point with the grduted scle. NOTE: Normlly min ering journls wer evenly nd re not out of round. If ering is eing fitted to n out of round journl of mm (0.001 in.) mximum, e sure to fit to the mximum dimeter of the journl. If the ering is fitted to the minimum dimeter nd the journl is out of round mm (0.001 in.) mximum, interference etween the ering nd journl will result in rpid ering filure. If the flttened guging plstic tpers towrd the middle or ends, the difference in clernce indictes tper or n other irregulrity of the ering or journl. Pge 3B M JANUARY 2014

21 Mesure the journl with micrometer if the flttened guging plstic indictes more thn mm (0.001 in.) difference. Mesuring clernce with plstic guge - Compressed guging plstic - Scle Production Service Min Bering Clernce Numer 1 Numer 2, 3, 4 Numer 5 Numer 1 Numer 2, 3, 4 Numer mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) 6. If the ering clernce is within specifictions, the ering insert is stisfctory. If the clernce is not within specifictions, replce the insert. Alwys replce oth upper nd lower inserts s set. 7. A stndrd or mm (0.001 in.) undersized ering my produce the proper clernce. If not, it will e necessry to regrind the crnkshft journl for use with the next undersized ering. IMPORTANT: After selecting new ering, recheck clernce. 8. Check clernce with newly selected ering. If the ering clernce is within specifictions, the ering insert is stisfctory. If not, repet previous steps. 9. Proceed to the next ering. After ll erings hve een checked, oil nd instll the selected erings nd rotte the crnkshft to check for excessive drg. Crnkshft End Ply 1. Firmly force the crnkshft rerwrd. 2. Firmly force the crnkshft forwrd. 90-8M JANUARY 2014 Pge 3B-21

22 3. Mesure the clernce t the front end of the rer min ering with feeler guge s shown. Mesuring crnkshft end ply End ply (thrust clernce) mm ( in.) Preliminry Inspection IMPORTANT: All mesurements should e tken when components re t room temperture. 1. Connecting rod. Check for twisted or ent connecting rods.. Inspect for nicks nd crcks. c. Inspect for dmge to the ering cp or olt threds. d. Replce dmged connecting rods. 2. Connecting rod erings NOTE: Refer to Min Bering Inspection for exmples of common ering filures.. Inspect the connecting rod erings for crters, pockets, or flttened sections.. Inspect the connecting rod erings for excessive scoring, discolortion, or dmge. c. Inspect the connecting rod erings for dirt or deris emedded in the ering mteril. d. Replce dmged or fulty erings. Piston Inspection NOTE: Cylinder ore nd tper must e within specifictions efore pistons cn e considered for reuse. 1. Inspect the piston for crcked ring lnds, skirts nd pin osses, wvy or worn ring lnds, scuffed or dmged skirts, nd eroded res t the top of the piston. 2. Inspect the ring grooves for nicks nd urrs tht my cuse the rings to ind. 3. Inspect the piston for wer y checking the piston to ore clernce:. Mesure the piston dimeter 11.0 mm (0.433 in.) from the ottom of the skirt t right ngle to the piston pin ore s shown. Mesuring piston dimeter - Piston dimeter - Mesurement loction Mesure the cylinder ore dimeter with telescope guge. Refer to Piston Selection. c. Sutrct the piston dimeter from the cylinder ore dimeter to determine piston to ore clernce. d. Replce the piston if the piston to ore clernce is less thn specified. Refer to Piston Selection for cylinder reconditioning nd piston replcement. Pge 3B M JANUARY 2014

23 Production Service Piston Bore Clernce 4. Insert the pproprite type of piston ring into ech of the piston ring grooves. 5. Roll the ring round the groove to ensure tht the ring moves freely round the entire piston. If the ring inds, check the piston ring groove for deposits. Clen out ll deposits mm ( in.) mm ( in.) mximum If the ring inds, check the piston ring groove for nicks or urrs. Minor internl dmge cn e dressed with fine file. If the piston ring groove is clen nd free of defects, check the groove with different ring. The ring used for inspection my e ent Checking piston ring grooves 6. Using feeler guge, mesure the clernce etween the piston ring nd the piston ring groove t severl points round the piston Mesuring piston ring to piston clernce 90-8M JANUARY 2014 Pge 3B-23

24 Groove clernce Groove clernce Top Compression Production Service Second Compression Production Service Oil Control mm ( in.) mm ( in.) mm ( in.) mm ( in.) Groove clernce Production Service 7. Replce the piston if groove clernce exceeds the specified limit. Piston Ring Gp Inspection IMPORTANT: Fit ech compression ring to the cylinder in which it is going to e used. 1. Insert piston ring into the cylinder ore. 2. Use n inverted piston to push the piston ring 6.0 mm (1/4 in.) into the cylinder ore. NOTE: Ensure tht the piston nd ring re squre with the cylinder wll. 3. Remove the piston. 4. Using feeler guge, mesure the piston ring gp mm ( in.) mm ( in.) Mesuring piston ring gp Top compression ring gp Production mm ( in.) Service mm ( in.) Second compression ring gp Production mm ( in.) Service mm ( in.) Oil control ring gp Production mm ( in.) Service mm ( in.) 5. Replce ring if the gp exceeds service limits. If the ring gp is elow specifictions, remove the ring nd try nother. Pge 3B M JANUARY 2014

25 Assemly Piston 1. Assemle the piston nd connecting rod using the piston pin press. Follow the tool mnufcturer's instructions. - Piston pin press - Piston pin c - Piston nd rod ssemly c Kent Moore piston pin press Prt Numer J24086 C 2. Check tht the piston will pivot nd slide freely on the piston pin. Piston nd rod ssemlies tht ind hve piston pin or ore out of specifiction nd require replcement of the piston nd pin ssemly. 3. If new connecting rod hs een instlled, mrk the connecting rod nd cp (on the slots for the connecting rod ering tngs) with the cylinder numer in which it will e instlled. Piston Ring Instlltion IMPORTANT: All compression rings re mrked on the upper side of the ring. When instlling compression rings, ensure tht the mrked side is towrd the top of the piston. NOTE: Oil control rings re three piece type, consisting of two rings nd spcer. 1. Select rings pproprite for the cylinder ore nd piston size. 2. Instll the oil control ring spcer in its groove. 3. Hold the spcer ends together nd instll the lower oil control ring with its gp properly locted. c e d Ring gp loctions - Oil ring spcer gp - Oil ring gps c - Lower compression ring gp d - Upper compression ring gp e - Front of engine Instll the upper oil control ring with its gp properly locted. 5. Flex the oil ring ssemly to ensure tht the rings move freely. IMPORTANT: Use the piston ring expnder for compression ring instlltion. Piston Ring Expnder Using piston ring expnder, instll the lower nd upper compression rings with the mrked side up. Piston nd Rod Instlltion IMPORTANT: Cylinder ores must e thoroughly clen efore piston instlltion. 90-8M JANUARY 2014 Pge 3B-25

26 IMPORTANT: When ressemling the pistons nd connecting rods, the following must e kept in mind: The piston nd pin re mchine fitted to ech other nd must remin together s mtched set. Do not mix pistons nd pins. If the originl pistons or connecting rods re eing used, instll them into the cylinder from which they were removed. The connecting rod ering tngs re lwys oriented towrd the outside of the engine lock Connecting rod ering tngs The notch on the top of the piston must e positioned towrd the front of the engine (wter pump end). - Piston notch Cylinder ore preprtion:. Clen the cylinder ores with light honing oil, s necessry.. Clen with hot wter nd detergent. c. Rinse thoroughly. d. Lightly oil the cylinder ores with clen, lint free white cloth, with engine oil. Repet until the cloth remins clen. e. Wipe down the cylinder ores finl time with clen, lint free white cloth. Tue Ref No. Where Used Prt No. 139 Mercury 25W-40 Synthetic Blend 4-Stroke Engine Oil Cylinder wlls 92-8M Rotte the crnkshft until the crnkpin is t efore ded center (BDC) for the cylinder tht is redy for the first piston to e instlled. 3. Crefully wipe ny foreign mteril from the connecting rod erings nd the connecting rod ering fitting surfces. IMPORTANT: Do not pply oil to the ck of the erings or the connecting rod ering mting surfces. Pge 3B M JANUARY 2014

27 4. Insert the ering shells into the connecting rod nd its mtching rod cp Lierlly luricte the connecting rod erings, pistons, rings, nd cylinder wlls. Tue Ref No. Where Used Prt No Position ring gps s shown. Mercury 25W-40 Synthetic Blend 4-Stroke Engine Oil Connecting rod erings, pistons, rings, nd cylinder wlls 92-8M c e d Ring gp loctions - Oil ring spcer gp - Oil ring gps c - Lower compression ring gp d - Upper compression ring gp e - Front of engine Use the piston ring compressor nd compress rings M JANUARY 2014 Pge 3B-27

28 30399 Piston ring compressor use Piston ring compressor Prt Numer J8037 IMPORTANT: Be sure to instll new pistons in the sme cylinders for which they were fitted nd used pistons in the sme cylinder from which they were removed. Ech connecting rod nd ering cp should e mrked, eginning t the front of engine (1, 3, nd 5 from the left nk nd 2, 4, nd 6 from the right nk). Numers on the connecting rod nd ering cp must e on the sme side when instlled in the cylinder ore. If connecting rod is ever trnsposed from one lock or cylinder to nother, new erings should e fitted nd the connecting rod should e numered to correspond with the new cylinder numer. 8. Instll ech connecting rod nd piston ssemly in its respective ore with the connecting rod ering tngs towrd the outside of the engine lock nd the piston notch towrd the front of the engine. 9. Hold the piston ring compressor firmly ginst the engine lock until ll piston rings hve entered the cylinder ore. 10. Using wooden or plstic hmmer hndle, lightly tp the piston into its ore. 11. Apply luricnt to the threds nd mting fces of ech connecting rod cp nd screw. Tue Ref No. Where Used Prt No. 139 Mercury 25W-40 Synthetic Blend 4-Stroke Engine Oil Threds nd mting fces of connecting rod cp nd screws 92-8M NOTICE Connecting rods nd end cps re mtched sets. Mismtching the originl pirs will result in ctstrophic engine dmge. Instll ll connecting rods with their mtched end cps. Pge 3B M JANUARY 2014

29 12. Instll the connecting rod cp. c Instlling connecting rod cps - Connecting rod screws (2) - Connecting rod cp c - Lower ering hlf In two pss sequence, tighten connecting rod cp screws to the specified torque. Nm l in. l ft Connecting rod cp screw First Finl Lightly tp ech connecting rod ssemly prllel to the crnkpin to set side clernce. 15. Check rod ering clernce using plstic guge method. Refer to Connecting Rod Bering Clernce, Plstic Guge Method. 16. Mesure ll connecting rod side clernces etween the connecting rod cps. Mesuring connecting rod side clernce 6408 Rod side clernce mm ( in.) Connecting Rod Bering Clernce, Micrometer Method IMPORTANT: The micrometer method is the preferred method of determining connecting rod ering clernce. IMPORTANT: All mesurements should e tken when components re t room temperture. 90-8M JANUARY 2014 Pge 3B-29

30 Connecting rod erings re of the precision insert type nd do not use shims for djustment. Replce the ering if clernce is found to e excessive. Service erings re ville in stndrd size nd in. nd in. undersized for use with new nd used stndrd size crnkshfts. They re lso ville in in. nd in. undersized for use with reconditioned crnkshfts. NOTE: When removing connecting rod cp, you my find in. undersized ering. These re used during mnufcturing for selective fitting. 1. Wipe oth upper nd lower connecting rod erings clen with soft cloth. 2. Instll the upper nd lower connecting rod erings. 3. Instll the ering cp. 4. In two step sequence, tighten the ering cp screws to the specified torque. Nm l in. l ft Bering cp screws First Finl Use n inside dil indictor to mesure the connecting rod ering inside dimeter nd out of round nd tper. Mesure in severl plces pproximtely 90 prt nd verge the mesurements. IMPORTANT: Do not mesure inside dimeter close to the connecting rod nd ering split line. - Inside dil indictor - Assemled rod nd erings c - Split line c Record the mesurements. 7. Wipe the crnkshft connecting rod journl with clen cloth. Remove ny oil film. 8. Mesure the crnkshft connecting rod journl dimeter with micrometer. Tke second mesurement t position on the connecting rod journl t point 90 from the first mesurement. - Mesurement point "" - Mesurement point "" Dimeter Tper Out of round Production Service Production Service mm ( in.) mm ( in.) mximum mm ( in.) mximum mm ( in.) mximum mm ( in.) mximum Pge 3B M JANUARY 2014

31 NOTICE Indequte clernce or interference etween the ering nd its mting surfce will result in rpid ering wer nd ctstrophic component filure. Check ll ering clernces. 9. If the crnkshft rod ering journl dimeters re not within specifictions, replce or recondition the crnkshft. 10. If the crnkshft rod ering journl dimeters re within specifictions, determine ering clernce y sutrcting the crnkshft connecting rod journl outer dimeter from the inner dimeter of the ering from step 5. Clernce Production Service limit mm ( in.) mm ( in.) 11. If the clernce exceeds specifictions, select new, correct size ering, nd recheck the ering clernce. Connecting Rod Bering Clernce, Plstic Guge Method The plstic guge method is n optionl method of determining connecting rod ering clernce. Micrometer mesurement is the preferred method. 1. Wipe oth upper nd lower erings nd the crnkshft connecting rod journl with clen soft cloth. Remove ny oil film. 2. Instll the erings in the connecting rod nd cp. IMPORTANT: To otin ccurte mesurements the connecting rod nd upper ering must e seted ginst the connecting rod journl efore instlling the lower ering nd rod cp. 3. Rotte the crnkshft or move the connecting rod until the upper ering is fully seted ginst the connecting rod journl eing mesured. IMPORTANT: Position the plstic guge on the crnkshft journl so tht it will e centered s it lys cross the ering shell. 4. Plce piece of guging plstic prllel to the crnkshft on the middle of the open crnkshft connecting rod journl surfce s shown. Instll the guging plstic the full width of the journl Plstic guge plcement 5. Instll the ering cp. 6. Tighten the ering cp screws in two steps to the specified torque. Nm l in. l ft Bering cp screws First Finl IMPORTANT: Do not rotte the crnkshft while the guging plstic is etween the ering nd journl. 90-8M JANUARY 2014 Pge 3B-31

32 7. Without rotting the crnkshft, remove the ering cp nd use the scle on the guging plstic envelope to mesure the guging plstic width t the widest point. - Compressed guging - Scle Journl clernce Production Service mm ( in.) mm ( in.) 8. If the clernce is not within specifictions, select new, correct size ering nd recheck the clernce. NOTE: If clernce cnnot e rought to within specifictions, the crnkshft connecting rod journl will hve to e ground undersized. If the connecting rod journl is lredy t mximum undersized, replce the crnkshft. 9. Cot the selected ering surfce with oil. 10. Instll the connecting rod cp Tighten the ering cp screws in two steps to the specified torque. Nm l in. l. ft. Bering cp screws, First Finl + 70 Connecting Rod Side Clernce 1. When ll connecting rod erings hve een instlled, tp ech rod lightly (prllel to the crnkshft) to estlish clernce. Pge 3B M JANUARY 2014

33 2. Mesure the side clernce etween ech pir of connecting rod cps Mesuring connecting rod side clernce Rod side clernce mm ( in.) Oil Pump Inspection IMPORTANT: Pump gers nd ody re not serviced seprtely. If the pump gers or ody re dmged or worn, replcement of the entire oil pump ssemly is necessry. 1. Inspect the pump ody nd cover for crcks or excessive wer. 2. Inspect the pump gers for dmge nd excessive wer, such s chipped teeth nd glling. 3. Check the ger shfts in the pump ody for glling, scoring, or excessive shft to ore clernce. 4. Inspect the inside of the pump cover for wer tht would permit oil to lek pst the gers. 5. Inspect the pickup screen nd suction pipe ssemly for dmge or lockge. 6. Check the pressure regultor vlve for smooth, noninding fit in its ore in the oil pump cover. 7. Inspect the oil pump loctor dowel pins for dmge nd proper height. - Dowel pins - Oil pump dowel pin height Oil pump dowel pin Height 6.4 mm ( in.) 90-8M JANUARY 2014 Pge 3B-33

34 Ressemly 1. Lierlly cot the surfces of the pressure regultor vlve, pressure relief spring, nd the pressure regultor ore in the oil pump ody with luricnt. Tue Ref No. Where Used Prt No. 139 Mercury 25W-40 Synthetic Blend 4-Stroke Engine Oil! CAUTION Oil pump components 92-8M The pressure regultor vlve is spring loded, retined y snp ring. The force of the spring cn cuse injury during removl. Use cution when disssemling components nd wer protective eye equipment. 2. Instll the pressure regultor vlve nd new pressure relief spring if reusing the existing pump nd retining pin. 3. Lierlly cot the surfces of the oil pump gers nd shfts with luricnt. Tue Ref No. Where Used Prt No. 139 Mercury 25W-40 Synthetic Blend 4-Stroke Engine Oil 4. Instll the drive ger in the pump ody. Surfces of oil pump gers nd shfts 92-8M Instll the idler ger in the pump ody with the smooth side of the ger towrd the pump cover. 6. Align the ger teeth mrks mde during disssemly. 7. Fill the ger cvity with engine oil. 8. Instll the oil pump cover nd cover screws. Tighten the screws in digonl pttern to the specified torque. - Cover - Screws (4) Nm l in. l ft Oil pump cover screw Turn the oil pump driveshft y hnd to ensure smooth pump opertion. IMPORTANT: Improperly instlling the intke pipe cn cuse improper luriction, dmging the engine. Instll so the pickup screen is prllel to the ottom of the oil pn. Do not twist, sher, or collpse the oil pump intke pipe during instlltion. 10. If the pickup screen nd pipe ssemly were removed:. Mount the pump in soft jwed vise.. Apply selnt to the end of new suction pipe. Tue Ref No. Where Used Prt No. 9 Loctite 567 PST Pipe Selnt End of new suction pipe Pge 3B M JANUARY 2014

35 c. Using the suction pipe instller tool, tp the suction pipe in plce with plstic mllet. c d - Oil pump - Pickup screen c - Oil suction pipe instller d - Plstic mllet Instlltion Kent Moore oil suction pipe instller d. Confirm tht the pickup screen is prllel to the ottom of the oil pn when instlled. 1. Align the oil pump driveshft with the distriutor driveshft. IMPORTANT: Do not reuse the oil pump driveshft retiner. Prt Numer J21882 c d c Driveshft - Driveshft retiner c - Oil pump d - Screw 2. Instll the oil pump driveshft, new driveshft retiner, nd the oil pump to the rer min ering cp. 3. Tighten the oil pump screw to the specified torque. Nm l in. l ft Oil pump screw (to rer crnkshft ering cp) First Finl M JANUARY 2014 Pge 3B-35

36 Cmshft nd Blnce Shft Inspection Blnce Shft - Blnce shft - Driven ger olt c - Blnce shft driven ger d - Blnce shft retiner olts e - Blnce shft retiner e IMPORTANT: The lnce shft nd the lnce shft front ering re serviced only s n ssemly. Do not remove the lnce shft front ering from the lnce shft. 1. Inspect the front ering for dmge nd smoothness of opertion. 2. Inspect the rer ering for dmge. 3. Inspect the lnce shft, retiner, nd gers for wer or dmge. 4. Inspect the lnce shft journls for wer or dmge. Cmshft 1. Inspect the cmshft thrust plte for dmge. Replce if dmged or worn. 2. Inspect the cmshft for worn, scored, or dmged ering journls or loes. 3. Inspect the cmshft for olt hole threds. 4. Inspect the cmshft sprocket loctor pin. 5. Mesure the cmshft ering journls with micrometer. If journls re not within specifictions, the cmshft should e replced. c Journl dimeter Journl out of round d mm ( in.) mm ( in.) mximum 6. Mesure for ent cmshft or excessive cmshft runout with dil indictor. If the runout exceeds the specified mount, the cmshft should e replced. Checking cmshft runout - Cmshft - Dil indictor Pge 3B M JANUARY 2014

37 Cmshft runout mm ( in.) mximum Instlltion Blnce Shft 1. Luricte the lnce shft front ering. Tue Ref No. Where Used Prt No. 139 Mercury 25W-40 Synthetic Blend 4-Stroke Engine Oil 2. Using the lnce shft instller nd the driver hndle instll the lnce shft. Blnce shft front ering 92-8M Driver hndle - Blnce shft instller Blnce shft instller Driver hndle 3. Instll the lnce shft retiner nd olts. Prt Numer J36996 J M JANUARY 2014 Pge 3B-37

38 4. Tighten the olts to the specified torque. - Bolts - Blnce shft retiner Nm l in. l ft Blnce shft retiner olts Instll the lnce shft driven ger onto the lnce shft. 6. Apply Loctite 242 Thredlocker dhesive to the threds of the lnce shft driven ger screw. - Blnce shft driven ger screw - Driven ger Tue Ref No. Where Used Prt No. 66 Loctite 242 Thredlocker Blnce shft driven ger screw threds Instll the lnce shft driven ger screw, s follows:. Secure the lnce shft with wrench.. Instll nd tighten the lnce shft driven ger screw to the specified torque. Nm l in. l ft Blnce shft driven ger screw First Finl Remove the wrench from the lnce shft. Pge 3B M JANUARY 2014

39 9. Rotte the lnce shft y hnd to ensure clernce etween the lnce shft nd the vlve lifter pushrod guide. Cmshft NOTE: If the lnce shft does not rotte freely, ensure the retining ring on the lnce shft front ering is seted on the cse. 1. Instll three 5/16 18 x 5 in. olts into the cmshft olt holes. 2. Luricte the cmshft journls with engine oil nd instll the cmshft. Be creful not to dmge the erings. Tue Ref No. Where Used Prt No. 139 Mercury 25W-40 Synthetic Blend 4-Stroke Engine Oil 3. Luricte the cmshft loes with Johnson EP Lue or equivlent. Cmshft journls 92-8M Tue Ref No. Where Used Prt No. Johnson EP Lue Prt Numer Remove the three olts in the cmshft olt holes. Cmshfts nd cmshft loes 5. Cot the threds of the cmshft thrust plte retiner olts with Loctite 242 Thredlocker dhesive. Otin Loclly Tue Ref No. Where Used Prt No. 66 Loctite 242 Thredlocker Cmshft thrust plte retiner olt threds Instll the cmshft thrust plte retiner nd olts. Tighten the olts to the specified torque. Nm l in. l ft Cmshft thrust plte retiner olts Instll the lnce shft drive ger Blnce shft drive ger 8. Rotte the engine cmshft so tht the timing mrk on the lnce shft drive ger is in the 12 o'clock position. 9. Remove the lnce shft driven ger. 10. Rotte the lnce shft so tht the timing mrk on the lnce shft driven ger is in the 6 o'clock position. 11. Position the lnce shft driven ger onto the engine cmshft. 90-8M JANUARY 2014 Pge 3B-39

40 12. Ensure tht the lnce shft drive ger nd the lnce shft driven ger timing mrks re ligned. - Timing mrks Timing Chin Inspection 1. Inspect the timing chin for wer nd dmge. 2. Inspect the sprockets for wer nd dmge. 3. Replce the components s necessry. Assemly 1. Instll the crnkshft lncer key into the crnkshft keywy Crnkshft keywy 2. Align the keywy of the crnkshft sprocket with the crnkshft lncer key. 3. The crnkshft lncer key should e prllel to the crnkshft or with slight incline. Pge 3B M JANUARY 2014

41 4. Instll the sprocket on the crnkshft y using the rer pinion ering rce instller tool. - Rer pinion ering rce instller - Crnkshft sprocket Rer pinion ering rce instller 5. Align the mrks on the crnkshft nd the cmshft sprockets. 6. Instll the cmshft sprocket nd timing chin. Tighten the sprocket screws to the specified torque. Prt Numer J5590 Nm l in. l ft Cmshft sprocket screws Checking Timing Chin Deflection 1. Rotte the cmshft (in either direction) to plce tension on one side of the chin. 2. Estlish nd mrk reference point on the lock (on tut side of chin) nd mesure from this point to the chin. Mesuring timing chin deflection 3. Rotte the cmshft in the opposite direction to provide slck in the chin. 4. Push the chin in towrd the sprockets nd mesure the distnce etween the reference point nd timing chin. 5. The deflection is the difference etween these two mesurements. If the deflection exceeds specifiction, the timing chin should e replced Chin deflection 11 mm ( in.) mximum 90-8M JANUARY 2014 Pge 3B-41

42 Instlltion Instll the crnkshft position reluctor ring. - 58X reluctor ring Crnkcse Front Cover Instlltion NOTE: New front covers re complete with gsket nd crnkshft sel. 1. Luricte the new crnkshft sel with clen engine oil. Tue Ref No. Where Used Prt No. 139 Mercury 25W-40 Synthetic Blend 4-Stroke Engine Oil Front cover crnkshft sel 92-8M Instll the new crnkcse front cover, ensuring tht the holes in the cover lign with the dowel pins in the lock. Tighten the screws to the specified torque. Nm l in. l ft Front cover screw X reluctor ring - 58X reluctor ring - Crnkcse front cover c - Front crnkshft sel c Instll new crnkshft position sensor O ring sel nd luricte the sel with clen engine oil. Pge 3B M JANUARY 2014

43 IMPORTANT: The crnkshft position sensor must e fully seted in the front cover. Errtic engine opertion cn occur if sensor is not properly instlled. Tue Ref No. Where Used Prt No. 139 Mercury 25W-40 Synthetic Blend 4-Stroke Engine Oil 4. Instll the crnkshft position sensor. Ensure tht the sensor is fully seted in the cover. Crnkshft position sensor O-ring sel 92-8M c - Screw - Crnkshft position sensor c - Crnkcse front cover 5. Instll the crnkshft position sensor screw. Tighten the screw to the specified torque. Nm l in. l ft Crnkshft position sensor screw Instll the crnkshft lncer. Tighten the screw to the specified torque. Nm l in. l ft Crnkshft lncer screw Instll the wter circulting pump. Tighten the screws to the specified torque. Nm l in. l ft Wter circulting pump screws Instll the hoses to the wter circulting pump. 9. Instll the crnkshft pulley. Tighten the screw to the specified torque. Nm l in. l ft Crnkshft pulley screws Oil Pn Inspection Inspect the oil pn for crcks, holes, wrped seling surfces, or other dmge. 90-8M JANUARY 2014 Pge 3B-43

44 2. Replce the oil pn if necessry. - Bolt (4) - Oil pn c - Oil pn ffle c 3. Remove nd clen the oil pn ffle Instll the oil pn ffle nd the olts. Tighten the oil pn ffle olts to the specified torque. Nm l in. l ft Oil pn ffle olt Instlltion IMPORTANT: The dhesive sets up in out 15 minutes. Complete the ssemly while the dhesive is still wet. 1. Apply 5 mm (0.197 in.) wide nd 25 mm (1.00 in.) long ed of dhesive to oth the right nd left side joints of the rer sel retiner nd joints of the front cover Joints of the front cover Pge 3B M JANUARY 2014

45 53625 IMPORTANT: Alwys instll new oil pn gsket. Joints of the rer sel retiner NOTE: The oil pn gsket nd oil pn must e instlled nd the fsteners tightened while the dhesive is still wet to the touch. 2. Instll new oil pn gsket. 3. Instll the new oil pn gsket into the groove in the oil pn. IMPORTANT: The oil pn lignment must lwys e flush or forwrd no more thn 0.3 mm (0.011 in.) from the rer fce of the engine lock. 4. Instll the oil pn onto the engine lock. Press the oil pn gsket into the grooves of the engine front cover nd crnkshft rer oil sel housing. 5. Slide the oil pn ck ginst suitle strightedge. 6. Instll the oil pn olts nd nuts, ut do not tighten. - Oil pn to housing mesurement points M JANUARY 2014 Pge 3B-45

46 7. Mesure the pn to trnsmission housing clernce using feeler guge nd strightedge. Use feeler guge to check the clernce etween the oil pn to housing mesurement points. If the clernce exceeds 0.3 mm (0.011 in.) t ny of the three oil pn to housing mesurement points, then repet the step until the oil pn to housing clernce is within the specifiction. The oil pn must lwys e forwrd of the rer fce of the engine lock. NOTE: If the clernce is more thn 0.3 mm (0.011 in.), powertrin durility my e reduced. 8. Tighten the oil pn olts nd nuts in sequence (1 12) to the specified torque. Tighten the oil pn stud nuts nd the oil pn olt or stud to the specified torque Nm l in. l ft Oil pn stud nut Oil pn olt or nut Instll the gskets nd T fitting over the oil drin hose ssemly, prtilly thred into the oil pn. Position the T fitting so the dipstick tue se will ttch to the T fitting. 10. Securely tighten the oil drin tue to the oil pn. d 11. Tighten the oil drin nut to the specified torque. c e Gsket - T fitting c - Attch dipstick fitting d - Gsket e - Oil drin hose ssemly Nm l in. l ft Oil drin nut Pge 3B M JANUARY 2014

47 12. Instll the pproprite engine oil dipstick. - Dipstick - Dipstick tue c - Clmp c Cylinder Hed Inspection Cylinder Hed 1. Inspect the seling surfces for urrs, scrtches, deep nicks, erosion, or other dmge. 2. Inspect for crcks in exhust ports, wter jckets, nd comustion chmers (especilly round sprk plug holes nd vlve sets). 3. Replce the cylinder heds if necessry. 4. Inspect for rusted, dmged, or leking core plugs. Replce core plugs if necessry. 5. Inspect for corrosion round cooling pssges. 6. Check the fltness of cylinder hed gsket surfces (hed, exhust, nd intke gskets) using mchinist's strightedge nd feeler guges. Tke mesurements digonlly cross the cylinder hed from ll four corners nd stright down the center of the cylinder hed lengthwise. Hed deck shown, exhust nd intke decks re similr - Cylinder hed deck - Mchinist's strightedge c - Feeler guge c Surfce fltness At exhust mnifold deck At engine lock deck (with n 152 mm [6.0 in.] re) At intke mnifold deck Intke mnifold fltness 0.05 mm ( in.) 0.10 mm ( in.) 0.10 mm ( in.) 0.10 mm ( in.) 7. If mesured vlue is greter thn specified, the cylinder hed must e repired to specifictions or replced. 90-8M JANUARY 2014 Pge 3B-47

48 Vlve 1. Inspect the vlves for urned heds, crcked or pitted fces, or dmged stems. - Crcked nd pitted fce - Dmged stem IMPORTANT: Excessive vlve stem to ore clernce will cuse excessive oil consumption nd possily roken vlves. Insufficient clernce will result in noisy, inding vlves. 2. Mesure the vlve stem dimeter in three plces. 3. If the mesured vlue is less thn the specified limit, the vlve must e replced Intke Production stem dimeter Exhust mm ( in.) Service stem oversize dimeter Exhust only mm ( in.) 4. Mesure the vlve hed mrgin. 5. If the mesured vlue is less thn specified, the vlve must e replced Mrgin fter surfcing Intke 0.79 mm ( in.) minimum Vlve Stem to Bore Clernce 1. Using vlve with specified stem dimeter or new vlve, mesure vlve stem clernce. 2. Attch dil indictor to the cylinder hed. Position it ginst the vlve stem nd close to the vlve guide. Pge 3B M JANUARY 2014

49 3. Holding the vlve hed off the set out 2 mm (1/16 in.), move the vlve stem side to side in the guide s shown. Compre the stem clernce with the specifictions Mesuring stem clernce Production Service Intke Exhust Intke Exhust mm ( in.) mm ( in.) mm ( in.) mm ( in.) 4. If the clernce exceeds specifictions on the exhust vlve nd exhust guide: it is necessry to rem the vlve guide nd instll vlve with n oversized stem. Refer to Repir Vlve Guide Bore. 5. If the clernce exceeds specifictions on the intke vlve nd intke guide: it is necessry to replce the cylinder hed. Intke vlves re not ville with oversize stems. Vlve Springs 1. Use vernier cliper to mesure the vlve spring free length. Replce the spring if it is more or less thn the specified limit Free length 51.3 mm (2.02 in.) 90-8M JANUARY 2014 Pge 3B-49

50 2. Mesure the vlve for squreness Replce vlve spring if not squre. 4. Use spring compressor to mesure the vlve spring tension. Replce the spring if the mesured vlue is less thn the specified limit. - Vlve spring compressor - Torque wrench Repir Vlve spring compressor Pressure Vlve closed Vlve open Prt Numer J N (76 84 l) t 43.2 mm ( in.) N ( l) t 32.3 mm ( in.) Vlve Reconditioning 1. Recondition the vlve fce to the proper ngle if the vlve fce is pitted or worn. 2. Mesure the vlve mrgin. If the vlve mrgin is less thn the specified mount fter reconditioning, replce the vlve. Pge 3B M JANUARY 2014

51 NOTE: Severl different types of equipment re ville for reconditioning vlves. The mnufcturer's recommendtion should e crefully followed to ttin proper results Exhust - Mrgin - Fce ngle Intke Fce ngle Intke 45 Exhust 45 Mrgin fter surfcing Intke 0.79 mm ( in.) minimum Vlve Guide Bore IMPORTANT: Mesure the vlve stem dimeter of oth the intke nd exhust vlve, s vlve stem dimeter my or my not e the sme for oth vlves. 1. If exhust vlves with oversize vlve stems re required, rem vlve guide ores Vlve guide remer Vlve guide remer Prt Numer NLA 90-8M JANUARY 2014 Pge 3B-51

52 Production stem dimeter Intke Exhust mm ( in.) Service stem oversize dimeter Exhust only mm ( in.) 2. Remove the shrp corner creted y the remer t the top of the vlve guide. 3. Instll the vlve with the oversized stem. 4. Mesure the vlve stem to ore clernce. Vlve Set IMPORTANT: Regrdless of the type of equipment, it is essentil tht the vlve guide ores e free from cron or dirt to chieve proper centering of the pilot in the vlve guide, ensuring concentricity when reconditioning the vlve sets. NOTE: Severl different types of equipment re ville for reconditioning vlve sets. Equipment mnufcturer's recommendtions should e followed to ttin proper results. 1. Recondition the vlve sets if pitted or worn. d c Typicl 3 ngle vlve set - Top correction cut ngle - Set ngle c - Bottom correction cut ngle d - Set width Set ngle 46 Top correction cut ngle Intke nd exhust 30 Bottom correction cut ngle 60 Width Intke mm ( in.) Exhust mm ( in.) 2. Mesure the vlve set concentricity. Pge 3B M JANUARY 2014

53 3. Recondition the set if mesured vlue exceeds specified limit Mesuring vlve set concentricity Runout Intke Exhust 0.05 mm ( in.) mximum Cylinder Hed Ressemly IMPORTANT: Instll ech vlve in the port from which it ws removed or for which it hs een fitted. IMPORTANT: Intke vlve stem oil sels re lck. Exhust vlve stem oil sels re red or they re rown with white pint stripe on the outer dimeter. The letters "EX" re molded into the top of exhust vlve stem oil sels. 1. Assemle vlve into its proper port nd vlve guide. Apply clen engine oil to the vlve stem. Tue Ref No. Where Used Prt No. 139 Mercury 25W-40 Synthetic Blend 4-Stroke Engine Oil 2. Select the pproprite intke or exhust vlve stem oil sel. Vlve stem 92-8M Cot the outside surfce of the vlve stem ore nd ll surfces of the vlve stem oil sel with clen engine oil. Tue Ref No. Where Used Prt No. 139 Mercury 25W-40 Synthetic Blend 4-Stroke Engine Oil Outside surfce of vlve stem ore nd ll surfces of the vlve stem oil sel 4. Assemle the vlve stem oil sel onto the vlve stem nd slide down until it contcts the vlve spring set. 5. Press the vlve stem oil sel with the vlve stem sel instller until the tool contcts the spring set. 92-8M Typicl - Vlve stem sel - Vlve stem sel instller Kent Moore vlve stem sel instller Prt Numer J M JANUARY 2014 Pge 3B-53

54 6. For ll intke nd exhust vlves, ensure tht the instlled height (the gp etween the ottom edge of the vlve stem oil sel nd the cylinder hed vlve guide oss) is s specified. - Vlve guide oss - Bottom of vlve stem oil sel c - Instlled height (gp) c Vlve stem oil sel 7. Instll the vlve spring. 8. Plce vlve spring cp on the vlve spring. Instlled height NOTE: Mesured from the top of the vlve guide evel to the ottom of the oil stem sel.! CAUTION 1 2 mm ( in.) minimum Improperly compressed springs or improperly locked vlve cps could llow the spring to e ejected with tremendous force, which could cuse personl injury. Use cre when compressing the vlve springs or relesing the vlve spring compressor tool. 9. Compress the vlve spring using vlve spring compressor. Vlve spring compressor 10. Cot the vlve stem locks with luricnt to hold in plce. Prt Numer J8062 Tue Ref No. Where Used Prt No Instll the vlve stem locks. Needle Bering Assemly Luricnt Vlve stem locks 8M Pge 3B M JANUARY 2014

55 12. Confirm tht the vlve stem locks re properly seted in the grooves of the vlve stem. c d Vlve spring compressor - Vlve locks c - Vlve cp d - Vlve spring 13. Slowly relese the vlve spring compressor. 14. Set the ssemly y tpping the vlve stem with soft plstic hmmer. 15. Check the instlled height of the vlve springs using nrrow, thin scle. Mesure from the spring set to the top of the vlve spring. IMPORTANT: To ensure correct mesurement, mesure spring height from top of vlve spring, not top of the vlve. IMPORTANT: If mesurement exceeds specified height, instll vlve spring shim nd recheck. Do not shim vlve springs to give n instlled height less thn the minimum specified. Vlve spring instlled height Intke Exhust mm ( in.) minimum Typicl - Cut wy scle - Vlve spring instlled height Instlltion 1. Ensure tht the engine lock nd cylinder hed seling surfces re clen. 90-8M JANUARY 2014 Pge 3B-55

56 2. Plce new hed gsket in position over the dowel pins Crefully set the cylinder hed in plce over the dowel pins Cot the threds of the cylinder hed screws with selnt nd instll the screws finger tight Tue Ref No. Where Used Prt No. Loctite 565 PST Cylinder hed screw threds Otin Loclly Pge 3B M JANUARY 2014

57 5. Tighten cylinder hed screws to the specified torque in psses using numered sequence shown Lifters Inspection Cylinder Hed Torque Sequence Long screws 5, 8, 9, 12, nd 13 Medium screws 1 nd 4 Short screws 2, 3, 6, 7, 10, nd 11 Nm l in. l ft Cylinder hed screw Preferred method All screws in sequence In sequence ngle torque First Finl Cylinder hed screw Optionl method All screws In sequence Long screws +75 Medium screws +65 Short screws +55 First Second Finl Ensure tht the lifter set retiner clip is not roken or dmged. 2. Inspect the pushrod set. If the set is scuffed or worn, inspect the pushrod. 3. Inspect the outer lifter ody wll. If the wll is scuffed or worn, inspect the engine lock lifter ore. 4. Inspect the roller of the vlve lifter. If the roller is scuffed or worn, inspect the cmshft loe. 5. Ensure tht the oil hole is unostructed. 90-8M JANUARY 2014 Pge 3B-57

58 6. Inspect ll prts crefully. Replce the vlve lifter ssemlies tht re dmged or excessively worn. c d Lifter inspection points - Set retiner clip - Pushrod set c - Vlve lifter ody d - Roller e - Oil hole e Inspect the lifters for scoring or wer. Lifter Instlltion IMPORTANT: Do not instll used vlve lifters if new cmshft hs een instlled. IMPORTANT: Before instlling the vlve lifters, cot the cmshft loes nd vlve lifters with engine ssemly luricnt. Tue Ref No. Where Used Prt No. 136 Luriplte SPO 255 Cmshft loes nd vlve lifters Otin Loclly 1. Luricte nd instll the vlve lifters. Instll the vlve lifters in their originl loctions if eing reused Pge 3B M JANUARY 2014

59 Tue Ref No. Where Used Prt No. 136 Luriplte SPO 255 Vlve lifters Otin Loclly 2. Instll the lifter guide retiner. Tighten the olts to the specified torque Nm l in. l ft Vlve lifter guide retiner olt Rocker Arms nd Pushrods Inspection 1. Inspect ll contct surfces for excessive wer or scoring. 2. Inspect threds for dmge. 3. Inspect pivot points for inding or dmge. - Contct surfces - Threds c - Pivot points c M JANUARY 2014 Pge 3B-59

60 4. Inspect the pushrods. - Shft - Oil pssge c - End contct surfces c Inspect shft for ends.. Inspect for oil pssge restriction. c. Inspect for wer or scoring of the end contct surfces. 5. Replce ny dmged or excessively worn components. Instlltion 1. Luricte the outer surfces nd ends of the vlve pushrods. Tue Ref No. Where Used Prt No. 139 Mercury 25W-40 Synthetic Blend 4-Stroke Engine Oil Surfces nd ends of vlve pushrods 92-8M Instll the vlve pushrods in their originl loctions. Ensure tht the pushrods set in the lifter socket. 3. Instll the rocker rm supports Luricte the rocker rm nd rocker rm ll contct surfces. Pge 3B M JANUARY 2014

61 Tue Ref No. Where Used Prt No. 139 Mercury 25W-40 Synthetic Blend 4-Stroke Engine Oil 5. Luricte the threds of the vlve rocker rm studs. Rocker rm nd rocker rm ll contct surfces 92-8M Contct surfces - Threds Instll the rocker rm ssemlies in their originl loctions Tue Ref No. Where Used Prt No. 82 Premium Ger Luricnt Rocker rm stud threds K01 7. Tighten rocker rm olts to the specified torque. Nm l in. l ft Rocker rm olts M JANUARY 2014 Pge 3B-61

62 Intke Mnifold Assemly Upper nd Lower Intke Mnifolds - Upper intke mnifold - Gsket c - Lower intke mnifold c Refer to Section 5 for disssemly, clening, inspection, nd ressemly of the individul components. Instlltion IMPORTANT: Excessive mounts of dhesive or seler on gskets or component surfces my cuse improper seling resulting in intke mnifold ir or fluid leks. Do not pply excessive mounts of dhesive or seler. 1. Apply 4 mm (0.157 in.) ed of dhesive t ech end of the lower intke mnifold gsket on the cylinder hed side. Do not get seler into oil sending unit hole. NOTE: For proper dhesion, the lower intke mnifold gsket must e instlled while the dhesive is still wet. 2. Align the lower intke mnifold gskets with the loctor pins. Instll the lower intke mnifold gskets onto the cylinder heds. - Loctor pin - Loctor pin hole c - Are for selnt c Tue Ref No. Where Used Prt No. 128 Loctite 5900 Ultr Blck RTV Silicone Selnt Cylinder hed side of lower intke mnifold gskets Pge 3B M JANUARY 2014

63 3. Apply 5 mm (0.197 in.) wide ed of dhesive to the front nd rer of the engine lock s shown. Extend the dhesive ed 13 mm (0.51 in.) up on the intke gskets. IMPORTANT: Do not get seler into the oil sending unit hole t the rer of the engine. - Bed of dhesive - Oil sending unit hole Tue Ref No. Where Used Prt No. 128 Loctite 5900 Ultr Blck RTV Silicone Selnt 4. Cot the threds of the lower intke mnifold olts with selnt. Engine lock t the lower intke mnifold seling surfces Crefully instll the lower intke mnifold ssemly onto the engine lock. IMPORTANT: Avoid engine dmge. Crnkshft ering ore lignment my ecome distorted resulting in dmge to the crnkshft erings if intke mnifold fstener tightening sequence nd torque re done improperly. Alwys torque the olts in sequence to the specified mount in ech of the three psses required. NOTICE The crnkshft erings re mtched sets. Mismtching the erings cn result in engine dmge. Replce nd instll the erings in mtched pirs. 6. Tighten the lower intke mnifold olts to the specified torque in the sequence nd steps indicted. - Intke mnifold olts - Front M JANUARY 2014 Pge 3B-63

64 Tue Ref No. Where Used Prt No. 66 Loctite 242 Thredlocker Intke mnifold olts Nm l in. l ft First 3 27 Intke mnifold olts Second Finl Instll the injector ril with injectors. 8. Connect the injector wire hrness. 9. Instll the fuel line. 10. Instll the distriutor. Nm l in. l ft Distriutor hold down clmp olt MPI Connect ll ignition nd electricl leds. 12. Instll the ignition coil wire. 13. Instll other ignition components nd connect the wires. 14. Instll the rely rcket with relys. 15. Connect the crnkcse ventiltion hoses. 16. Connect the hoses to the thermostt housing. 17. Connect ny items tht were disconnected. 18. Refill the closed cooling system, if equipped. Vlve Cover Instlltion 1. Plce new rocker rm cover gsket in position. - Gsket - Rocker rm cover Instll the rocker rm cover. Tighten the olts to the specified torque. Nm l in. l ft. Rocker rm cover olt Instll ny items tht were removed. 4. Connect crnkcse ventiltion hoses. 5. Refer to Section 7 for Exhust Mnifold Instlltion. Pge 3B M JANUARY 2014

65 Flywheel Clening nd Inspection 1. Clen the mting surfces of the flywheel nd crnkshft. Remove ny urrs. The mting surfces must e clen, re metl. 2. Inspect the flywheel ring ger for worn nd missing teeth. 3. Inspect the splines in the drive plte or coupler for dmge or excessive wer. 4. Replce components s necessry. Instlltion NOTE: If the crnkshft is to e replced, ut the old pilot ushing is to e reused, the ushing cn e removed without dmge y filling the pilot ushing cvity with grese, then inserting n old trnsmission input shft into the ore of the ushing nd hitting it with hmmer. This will crete hydrulic pressure in the pilot ushing cvity forcing the ushing out. 1. Clen the mting surfces of the flywheel nd the crnkshft until the metl is re. 2. Align the dowel hole in the flywheel with the dowel in the crnkshft nd instll the flywheel. Tighten the screws in sequence to the specified torque. - Flywheel - Mounting screw (6) c - Torque sequence c Nm l in. l ft Flywheel mounting screws Check the flywheel runout:. Attch dil indictor to the engine lock.. Push in on the flywheel to remove ny crnkshft end ply. c. Turn the flywheel in the direction of norml engine rottion nd mesure flywheel runout t the smooth outer edge of the flywheel just inside the ring ger. - Dil indictor - Runout mesurement 6442 Runout mm ( in.) mximum 90-8M JANUARY 2014 Pge 3B-65

66 4. Insert three ruer umpers in the Alph coupler efore instlltion on the flywheel. Alph coupler Sterndrive models - Flywheel - Ruer umper (3) c - Coupler d - Tper hed screw (3) Brvo coupler Sterndrive models - Flywheel - Coupler c - Tper hed screw (3) Drive plte Inord nd TowSports models - Flywheel - Drive plte c - Tper hed screw (3) /8-16 3/4 tper-hed screw Qty. Prt Numer 3 3/8 16 3/4 tper hed screw Otin loclly NOTE: The tper hed screws re used to center the coupler to the flywheel. Pge 3B M JANUARY 2014

67 5. On Alph models: After ll three tper hed screws re tightened, remove one of the tper hed screws nd instll the originl mounting screw nd tighten to the specified torque. Repet this procedure for ech remining tper hed screw. 6. On Brvo nd inord models: After ll three tper hed screws re tightened, instll nd tighten three of the originl mounting screws in the open screw loctions. Remove the three tper hed screws nd instll the remining originl mounting screws. 7. Tighten the mounting screws to the specified torque. Nm l in. l ft Drive coupler or drive plte mounting screws Flywheel Housing Clening 1. Clen ll prts in solvent. 2. Dry the prts with compressed ir. Inspection 1. Inspect the flywheel housing for crcks, dmged olt or stud holes, nd excessive wer. Replce if necessry. 2. Inspect the guide dowels for the correct mount of protrusion from the engine lock. Repir if necessry. - Guide dowels (2) - Mesured protrusion 13 mm (0.5 in.) Instlltion 1. Align the flywheel housing on the guide dowels of the engine. IMPORTANT: The flywheel housing fsteners must e instlled in the sme loction s removed. 2. Instll the studs nd screws into their originl loctions. 3. Tighten the flywheel housing fsteners to the specified torque. Nm l in. l ft Flywheel housing fsteners Instll the flywheel housing cover. Tighten to the specified torque. Nm l in. l ft Flywheel housing cover screws Instll the ground wires. 6. Instll the power steering cooler (if equipped). 7. Instll the wter hoses. 8. Instll the power pckge in the ot. Crnkcse Front Cover Oil Sel (Without Removing Front Cover) Removl 1. Remove the elt nd crnkshft pulley. 2. Remove the crnkshft lncer. 90-8M JANUARY 2014 Pge 3B-67

68 3. Pry the sel out of the front of the cover with sel removl tool. Be creful not to distort the front cover or dmge the crnkshft. Sel removl tool Prt Numer J45000 Instlltion 1. Apply selnt to the crnkshft front cover mting surfce of the sel. Tue Ref No. Where Used Prt No. 128 Loctite 5900 Ultr Blck RTV Silicone Selnt 2. Luricte the ruer seling surfce. Crnkshft front cover sel mting surfce Tue Ref No. Where Used Prt No. 139 Mercury 25W-40 Synthetic Blend 4-Stroke Engine Oil Ruer seling surfce 92-8M Instll the new sel with the open end of the sel fcing inwrd. Using the crnkcse front cover ligner nd sel instller, drive the sel in until it sets. IMPORTANT: Do not use excessive force to drive in the sel. Crnkcse front cover ligner nd sel instller Crnkcse front cover ligner nd sel instller 4. Instll the crnkshft lncer. 5. Instll the crnkshft pulley nd elt. Min Berings, Without Crnkshft Removed Instlltion 1. Remove the cp on the min ering requiring replcement. 2. Remove the ering from the cp. Prt Numer J35468 Pge 3B M JANUARY 2014

69 3. Instll the min ering remover nd instller tool in the oil hole in the crnkshft journl. If this tool is not ville, cotter pin my e ent s shown nd used. - Min ering remover nd instller tool - Cotter pin Kent Moore min ering remover nd instller tool Prt Numer 4. Rotte the crnkshft clockwise s viewed from the front of the engine. This will roll the upper ering out of the engine lock. 5. Luricte new upper ering. 6. Insert the plin (unnotched) end etween the crnkshft nd the indented or notched side of the engine lock. 7. Rotte the ering into plce nd remove the tool from the oil hole in the crnkshft journl. 8. Luricte new lower ering nd instll in the ering cp J8080 Tue Ref No. Where Used Prt No. 139 Mercury 25W-40 Synthetic Blend 4-Stroke Engine Oil Upper nd lower ering 92-8M Instll the min ering cp in the originl loction with the mrkings pointing towrd the front of the engine. - Min ering cp - Bering cp mrks Tighten ll min ering cps, except the rer min ering cp. Nm l in. l ft Crnkshft min ering cp olt nd stud preferred method First Finl +73 Nm l in. l ft Crnkshft min ering cp olt nd stud optionl method Tighten the rer min ering cp. Using one of the methods descried elow. Preferred Method: 90-8M JANUARY 2014 Pge 3B-69

70 1. Do the first step torque on the rer min ering cp. Nm l in. l ft Crnkshft (min) ering cp olt nd stud preferred method 2. Using led hmmer, tp the end of the crnkshft to the rer. 3. Using led hmmer, tp the end of the crnkshft to the front. 4. Do the finl step torque on the ering cp. First Nm l in. l ft Crnkshft (min) ering cp olt nd stud preferred method Optionl Method: 1. Tp the end of the crnkshft to the rer nd then to the front with led hmmer. 2. Evenly tighten the rer min ering cp. Finl +73 Nm l in. l ft Crnkshft (min) ering cp olt nd stud optionl method Vlves nd Sels (Without Removing Hed) Vlve Spring Assemly Exploded View e d c Vlve - Vlve stem oil sel c - Vlve spring d - Vlve spring cp e - Vlve spring lock Vlve Spring Assemly Removl 1. Remove the rocker rm cover. 2. Remove the sprk plug of the cylinder eing serviced. 3. Remove the rocker rm ssemly. IMPORTANT: Keep ir pressure in the cylinder while springs, cps, nd vlve locks re removed or the vlves will fll into the cylinder. 4. Instll sprk plug port dpter in the sprk plug hole nd pply kp (20 30 psi) of compressed ir to hold the vlves in plce. Sprk plug port dpter SPX Prt Numer J23590 NOTE: If compressed ir is not ville, the piston my e rought up to TDC to keep the vlves from flling out of the cylinder hed. Pge 3B M JANUARY 2014

71 5. Insert vlve spring compressor under the rocker rm nut, compress the vlve spring, nd remove the vlve locks. c - Rocker rm nut - Vlve spring compressor c - Vlve locks Vlve spring compressor (cylinder hed on engine) 6. Crefully relese the vlve spring compressor. SPX Prt Numer J5892 D 7. Remove the vlve spring cp nd vlve spring. IMPORTANT: If compressed ir is not ville, do not turn the crnkshft while vlve springs, retiners, nd locks re removed or the vlves will fll into the cylinder. 8. Remove nd discrd the vlve stem oil sel. Typicl vlve stem oil sel M JANUARY 2014 Pge 3B-71