Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
3
A
72872
INDEX
Table of Contents Page
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-35
Page Torsional Damper . . . . . . . . . . . . . . . . . . . . . . . 3A-35
Torque Specifications 4.3L/4.3LX Engines . . . 3A-1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-35
Tools/Lubricants/Sealants . . . . . . . . . . . . . . . . . 3A-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-35
Engine Specifications . . . . . . . . . . . . . . . . . . . . . 3A-4 Crankcase Front Cover/Oil Seal . . . . . . . . . . . 3A-36
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-14 Oil Seal Replacement
Engine Identification . . . . . . . . . . . . . . . . . . 3A-14 (Without Removing Front Cover) . . . . . . . . 3A-36
Cylinder Head Identification . . . . . . . . . . . . 3A-14 Crankcase Front Cover . . . . . . . . . . . . . . . . . . 3A-37
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-37
Piston and Connecting Rods . . . . . . . . . . . 3A-15 Cleaning and Inspection . . . . . . . . . . . . . . . 3A-37
Camshaft and Drive . . . . . . . . . . . . . . . . . . . 3A-15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-37
Balance Shaft . . . . . . . . . . . . . . . . . . . . . . . . 3A-15 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-38
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . 3A-15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-38
Valve Train . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-15 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-38
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . 3A-15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-38
Lubrication System . . . . . . . . . . . . . . . . . . . 3A-16 Rear Main Oil Seal . . . . . . . . . . . . . . . . . . . . . . 3A-39
Bearing Failures . . . . . . . . . . . . . . . . . . . . . . . . 3A-17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-39
Piston Failures . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-17 Cleaning and Inspection . . . . . . . . . . . . . . . 3A-39
Pre-Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-40
Detonation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-18 Rear Main Oil Seal Retainer . . . . . . . . . . . . . . 3A-40
Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-19 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-40
Rocker Arm Cover . . . . . . . . . . . . . . . . . . . . . . . 3A-19 Cleaning and Inspection . . . . . . . . . . . . . . . 3A-40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-40
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-19 Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-40
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 3A-20 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-41
Rocker Arm/Push Rod . . . . . . . . . . . . . . . . . . . 3A-22 Checking Clearances . . . . . . . . . . . . . . . . . 3A-41
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-22 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 3A-42
Cleaning and Inspection . . . . . . . . . . . . . . . 3A-22 Connecting Rod Bearings . . . . . . . . . . . . . . . . 3A-43
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-22 Inspection and Replacement . . . . . . . . . . . 3A-43
Hydraulic Roller Valve Lifters . . . . . . . . . . . . . 3A-22 Connecting Rod/Piston Assembly . . . . . . . . . 3A-44
Locating Noisy Lifters . . . . . . . . . . . . . . . . . 3A-23 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-23 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3A-45
Cleaning and Inspection . . . . . . . . . . . . . . . 3A-24 Cleaning and Inspection . . . . . . . . . . . . . . . 3A-45
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-24 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3A-46
Valve Stem Oil Seal/Valve Spring . . . . . . . . . . 3A-25 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-47
Removal - Head Installed . . . . . . . . . . . . . . 3A-25 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-48
Valve Assembly (Exploded View) . . . . . . . 3A-25 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-48
Installation - Head Installed . . . . . . . . . . . . 3A-26 Cleaning and Inspection . . . . . . . . . . . . . . . 3A-49
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-26 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-49
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-26 Timing Chain and Sprocket . . . . . . . . . . . . . . . 3A-50
Cleaning and Inspection . . . . . . . . . . . . . . . 3A-26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-50
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-27 Cleaning and Inspection . . . . . . . . . . . . . . . 3A-50
Cylinder Head and Valve Conditioning . . . . . 3A-27 Installation - Timing Chain . . . . . . . . . . . . . 3A-50
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3A-27 Crankshaft Sprocket . . . . . . . . . . . . . . . . . . . . . 3A-51
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-28 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-51
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-28 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-51
Valve Guide Bore Repair . . . . . . . . . . . . . . 3A-29 Checking Timing Chain Deflection . . . . . . 3A-51
Valve Springs - Checking Tension . . . . . . . 3A-29 Balance Shaft/Gears . . . . . . . . . . . . . . . . . . . . . 3A-52
Valve Seat Repair . . . . . . . . . . . . . . . . . . . . 3A-30 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-52
Valve Grinding . . . . . . . . . . . . . . . . . . . . . . . 3A-30 Cleaning and Inspection . . . . . . . . . . . . . . . 3A-53
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3A-31 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-53
Dipstick Specifications . . . . . . . . . . . . . . . . . . . 3A-32 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-54
All Engines . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-32 Measuring Lobe Lift . . . . . . . . . . . . . . . . . . . 3A-54
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-33 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-33 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-55
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-33 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-55
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3A-34 Camshaft Bearings . . . . . . . . . . . . . . . . . . . . . . 3A-55
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-33 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-34 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-56
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3A-34 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-56
Cleaning and Inspection . . . . . . . . . . . . . . . 3A-34 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-57
Cleaning and Inspection . . . . . . . . . . . . . . . 3A-57
Oil Filter By-Pass Valve . . . . . . . . . . . . . . . . . . 3A-60
Inspection and/or Replacement . . . . . . . . . 3A-60
NOTE: Hold fuel pump using flat surface at outlet before tightening brass fitting.
Note : Hold fuel pump using wrench on flat surface at outlet before tightening brass fitting
LH ROTATION
FRONT
Firing Order
1-6-5-4-3-2
72976
PISTON
Production .0007-.0017 (0.0178-0.0431)
Clearance
Service .0027 (0.07) Maximum
PISTON RING
Top .0012-.0032 (0.0305-0.0813)
Groove Side Production
2nd .0012-.0032 (0.0305-0.0813)
Clearance
Service High Limit Production + .001 (0.025)
C
Compression
i
Top .010-.025 (0.254-0.508)
Production
G
Gap 2nd .010-.025 (0.254-0.508)
Service High Limit Production + .010 (0.254)
Groove Side Production .002-.007 (0.051-0.177)
C
Clearance Service High Limit Production + .001 (0.025)
Oil
Production .015-.055 (0.381-1.397)
Gap
Service High Limit Production + .010 (0.254)
PISTON PIN
Diameter .9270-.9273 (23.5458-23.5534)
Production .0002-.0007 (0.0051-0.0177)
Clearance in Piston
Service .001 (0.025) Maximum
Fit in Rod .0008-.0016 (0.0203-0.0406) Interference
FLYWHEEL
Runout .008 (0.203) Maximum
CYLINDER HEAD
Gasket Surface Flatness .004 (0.10) Overall Maximum
BALANCE SHAFT
Front Bearing Journal 1.1812-1.815 (30.002-30.010)
Rear Bearing Journal 1.4209-1.4215 (36.091-36.301)
Rear Bearing Inside Diameter
Production 1.5014-1.503 (37.525-37.575)
Assembled
Rear Bearing Outside Diameter Production 1.875-1.876 (46.875-46.900)
Rear Cylinder Block Housing Bore Production 1.873-1.874 (46.825-46.850)
Unit of Measurement
in. (mm)
CYLINDER BORE
PISTON CLEARANCE
PISTON PIN
Unit of Measurement
in. (mm)
CRANKSHAFT
Unit of Measurement
in. (mm)
VALVE SYSTEM
VALVE SPRING
Unit of Measurement
in. (mm)
FLYWHEEL
CYLINDER HEAD
BALANCE SHAFT
Unit of Measurement
in. (mm)
FLYWHEEL
CYLINDER HEAD
72875
Engine Identification
The MerCruiser Model can be determined by looking
at the last two letters of the engine code stamped into Engine Rotation
the cylinder block. This code number is stamped on
all MerCruiser power packages and replacement Engine rotation terminology at times has caused con-
partial engines, but not replacement cylinder block fusion. To clarify, engine rotation is determined by ob-
assemblies. serving flywheel rotation from the rear (transmission
or stern drive end) of the engine looking forward (wa-
If the engine serial number and/or model decals are
ter pump end).
missing, the engine code letters may help in deter-
mining the engine models. PROPELLER ROTATION IS NOT NECESSARILY
THE SAME as engine rotation. Do not rely on propel-
ler rotation in determining engine rotation.
a
a
72873
72424
Pre-Ignition Damage
72314
72315
72316
Installation
1. Clean sealing surfaces on cylinder head and
Front Mount rocker arm cover with degreaser.
2. Place new rocker arm cover gasket in position in
rocker arm cover.
a a
72318
72874
Rear Mount/Flywheel Housing
a - Gasket Used on MCM Engines Only a - Rocker Arm Cover Gasket
10. Remove intake manifold bolts, then remove in- a - Exhaust Crossover Port Opening in Gasket
take manifold and carburetor assembly.
1. Apply Quicksilver Perfect Seal to intake manifold
NOTE: If intake manifold requires replacement, gaskets especially around coolant passages
transfer all remaining parts to new manifold. (both sides).
2. Place gaskets on cylinder heads.
Cleaning and Inspection
1. Clean gasket material from all mating surfaces.
IMPORTANT: When cleaning cylinder head mat-
ing surface, do not allow gasket material to enter a
engine crankcase or cylinder head ports. a b
2. Inspect manifold for cracks or scratches. Ma-
chined surfaces must be clean and free of all
marks and deep scratches or leaks may result. 71850
3. Check intake passages for varnish buildup and a - Coolant Passages
other foreign material. Clean as necessary. b - Gaskets
72878
a 5 1 4 8
71850
a - RTV Sealer (Typical Both Ends) a
7 3 2 6
72878
1. Install push rods in their original locations. Be Valve lifters are retained in position and prevented
sure push rods seat in lifter socket. from rotating by two valve retainers, one on each side
of the engine beneath the intake manifold. Care
2. Install rocker arms, rocker arm balls and rocker should be exercised when installing the retainers to
arm nuts in their original locations. see that the flat portions of the lifters are properly po-
sitioned into the retainers.
3. Torque rocker arm nuts to 20 lb. ft. (27 N·m). No
valve adjustment is required. Valve lash is auto-
matically set when rocker arm nuts are torqued to
specification. a
71853
a - Retainer
b - Roller Lifter Flat Portion
Installation
b
IMPORTANT: It is recommended that the engine
oil be changed and a new oil filter be installed b
whenever servicing valve lifters or camshaft. 71853
71852
a - Lifter Retainer (Restrictor)
b - Fasteners
a. Intake manifold.
Spring
Removal - Head Installed
1. Remove: a
a. Rocker arm cover.
b. Spark plug of affected cylinder.
c. Rocker arm assembly.
2. Install air line adaptor tool (J-23590) in spark plug
hole and apply compressed air to hold valves in
place.
NOTE: If compressed air is not available, piston may
be brought up to TDC and used to keep valves from 72330
falling out of valve guides.
IMPORTANT: Do not turn crankshaft while valve
springs, retainers, and locks are removed or
valves will fall into cylinder.
a - Valve Guide Seal
3. Using valve spring compressor as shown, com-
press valve spring and remove valve locks.
Valve Assembly (Exploded View)
1
2
b 1
3
5 4
a 8
72881
9
10
a - Valve Spring Compressor (J-5892)
b - Rocker Arm Nut
72882
4. Slowly release valve spring compressor.
Remove cap, retainer or rotator, and valve
spring. 1 - Valve Locks
2 - Retainer
3 - Rotator
IMPORTANT: Keep air pressure in cylinder while
4 - Cap
springs, caps, and valve locks are removed or 5 - Valve Guide Oil Seal
valves will fall into cylinder. 6 - Valve Stem Oil Seal
7 - Damper
8 - Outer Spring
9 - Intake Valve
10- Exhaust Valve
4. While compressing valve spring with valve spring c. Rocker arm covers.
compressor, install oil seal in lower groove of d. Rocker arm assemblies and push rods (keep
valve stem, making sure seal is not twisted. A in order for reassembly in their original loca-
light coating of oil will help prevent twisting. tions).
5. Install valve locks (Quicksilver Needle Bearing e. Any components attached to front or rear of
Assembly Lubricant may be used to hold them in cylinder head.
place) and slowly release tool, making sure locks
seat properly in upper grooves of valve stem. f. Spark plugs.
g. Head bolts.
! CAUTION
b
The head gasket may be holding cylinder head to
block. Use care when prying off cylinder heads.
DO NOT damage gasket surfaces. DO NOT drop
cylinder heads.
a
72881
Cleaning and Inspection
a - Valve Spring Compressor (J-5892)
b - Rocker Arm Nut 1. Clean gasket material and sealer from engine
block and cylinder heads.
6. Install push rods and rocker arm assemblies.
2. Inspect sealing surfaces for deep nicks and
7. Torque rocker arm nuts to 20 lb. ft. (27 N·m). scratches.
8. Install rocker arm cover [torque to 50 lb. in. (5.5 3. Inspect for corrosion around cooling passages.
N·m)] and spark plug [torque to 15 lb. ft.
(20 N·m)]. 4. Clean head bolt threads and engine block bolt
hole threads, making sure no dirt, old oil or cool-
ant remain.
72883
b
72885
a - Straight Edge
b - Feeler Gauge
c - Take Measurements Diagonally Across Head (Both Ways)
72334 and Straight Down Center Head
72886
72308
a a
50668
72338
a b 9
10
75307
a - Quad Ring
b - Valve Seal
72882
4. Set valve spring (with damper installed) and cap
in place. 1 - Valve Locks
2 - Retainer
5. Place retainer on intake valve and/or rotator on 3 - Rotator
exhaust valve. 4 - Cap
5 - Valve Guide Oil Seal
6. While compressing valve spring with valve spring 6 - Valve Stem Oil Seal (See Important)
compressor, install oil seal in lower groove of 7 - Damper
valve stem, making sure seal is not twisted. A 8 - Outer Spring
9 - Intake Valve
light coating of oil will help prevent twisting. 10- Exhaust Valve
72884
05037
Cutaway Scale
1/2
(13)
a
25-7/16
(646)
26-7/8
(682)
FULL
3/4
(19)
ADD
72339
41092-1
MCM 72887
1
10
2 6
72145
72889
IMPORTANT: Mark gear teeth for reassembly with If pickup screen and pipe assembly was removed,
same teeth indexing. mount pump in a soft-jawed vise, apply Quicksilver
Perfect Seal to end of new pipe and, using oil pump
2. Remove idler gear and drive gear from pump
suction pipe installer (J-21882), tap the pipe in place
body.
with a hammer.
3. Remove retaining pin, spring, and pressure regu-
IMPORTANT: Oil internal parts liberally before in-
lator valve from pump cover.
stallation.
IMPORTANT: Do not remove pickup screen and
1. Install pressure regulator valve and related parts.
pipe assembly, unless replacement is necessary.
Loss of press fit condition could result in an air 2. Install drive gear in pump body.
leak and loss of oil pressure.
3. Install idler gear in pump body with smooth side
IMPORTANT: Do not disturb pickup screen on of gear toward pump cover opening. Align marks
pipe. This is serviced as an assembly. made in disassembly.
4. If pickup screen and pipe assembly requires re- 4. Fill gear cavity with engine oil.
placement, mount pump in a soft-jawed vise and
extract pipe from pump. 5. Install pump cover and torque attaching bolts to
80 lb. in. (9 N·m). Gen + 106 lb. in. (12 N·m).
INSTALLATION
a
72347
a - Crankcase Front Cover Seal Installer (J-35468)
73123
b c a
73124
! CAUTION
Installation
Ensure that cooling water supply is available be-
1. Install oil seal in cover with lip of seal toward in- fore starting the engine.
side of engine, using crankcase front cover seal
installer. Support cover around seal area with ap- 9. Start engine and check for water and oil leaks.
propriate tool as shown.
72348
Removal
1. Remove engine from boat. Refer to SECTION 2
- “Removal and Installation”.
b a
2. Refer to “Flywheel Housing” description in this
section and remove flywheel housing and related
parts.
3. Remove coupler.
4. Remove flywheel.
72353
72349 a
Alpha One Coupler
Inspection
1. Inspect splines in coupler for wear.
2. Check flywheel ring gear for worn and missing
teeth.
Installation
1. Clean mating surfaces of flywheel and crank-
shaft. Remove any burrs. Mating surfaces must
be clean bare metal.
2. Aligning dowel hole in flywheel with dowel in
crankshaft, install flywheel. Torque bolts to 75 lb. 72354
ft. (100 N·m).
3. Check flywheel runout as follows: a - Rubber Bumper
a. Attach a dial indicator to engine block. 4. Install drive coupler. Torque bolts to 35 lb. ft. (48
N·m).
b. Take readings around outer edge of flywheel.
Push in on flywheel to remove crankshaft end 5. Install flywheel housing and related parts. Torque
play. bolts to 30 lb. ft. (41 N·m).
6. Install flywheel housing cover. Torque bolts to 80
lb. in. (9 N·m).
7. Refer to Section 2 “Removal and Installation” and
install engine.
73126
a b
72355
b
a - Rear Seal c a
b - Seal Retainer
c - Slots (Three)
73127
Installation
1. Coat seal lips with clean 30W motor oil.
2. Install gasket and oil seal retainer with rear main
seal.
3. Coat threads of oil seal retainer fasteners with
Loctite Pipe Sealant with Teflon.
a 4. Install fasteners and torque to 133 lb. in.
(15 N·m).
72356
5. Install oil pan fasteners. Torque 1/4-20 threaded
fasteners to 80 lb. in. (9 N·m) and 5/16-18
threaded fasteners to 165 lb. in. (19 N·m).Torque
a - Rear Main Seal Installer (J-26817-A)
Gen+ engine oil pan nuts and bolts 18 lb. ft. (25
N·m)
Rear Main Oil Seal Retainer NOTE: A one-piece oil pan gasket may be re-used if
it is still pliable and is not cracked, torn or otherwise
damaged.
Removal
1. Remove oil pan.
Main Bearings
2. Remove oil seal retainer fasteners.
IMPORTANT: Before removing main bearing
3. Remove oil seal retainer. caps or connecting rod caps, mark them for reas-
sembly in their original locations.
a Main bearings are of the precision insert type and do
not use shims for adjustment. If clearances are found
to be excessive, a new bearing, both upper and lower
halves, will be required. Service bearings are avail-
able in standard size and .001 in., .010 in. and .020
in. undersize.
Selective fitting of both rod and main bearing inserts
is necessary in production in order to obtain close tol-
b erances. For this reason you may find one half of a
standard insert with one half of a .001 in. undersize
insert which will decrease the clearance .0005 in.
from using a full standard bearing.
a
IMPORTANT: If crankshaft has an undersize jour-
72464
nal and a new bearing is required, journal must
be reconditioned to accept a .010 or .020 in. un-
a - Fasteners dersize bearing as .009 in. undersize bearings are
b - Oil Seal Retainer not available for service.
To obtain accurate measurements while using Plasti- 5. On the edge of the gauging plastic envelope
gage, or its equivalent, engine must be out of the boat there is a graduated scale which is correlated in
and upside down so crankshaft will rest on the upper thousandths of an inch. Without removing the
bearings and total clearance can be measured be- gauging plastic, measure its compressed width
tween lower bearing and journal. (at the widest point) with the graduations on the
gauging plastic envelope as shown.
To assure the proper seating of the crankshaft, all
bearing cap bolts should be at their specified torque.
In addition, preparatory to checking fit of bearings,
the surface of the crankshaft journal and bearing
should be wiped clean of oil.
1. With the oil pan and oil pump removed, remove a b
bearing cap and wipe oil from journal and bearing
cap to be inspected.
2. Place a piece of gauging plastic the full width of
the bearing (parallel to the crankshaft) on the
journal as shown.
a 72358
b
72360
a 72622
72361
Inspection and Replacement
a - Gauging Plastic
IMPORTANT: Before you remove the connecting
rod cap, mark the side of the rod and cap with the
cylinder number to assure matched reassembly b. Install the bearing in the connecting rod and
of rod and cap. cap.
1. With oil pan and oil pump removed, remove the c. Install the bearing cap and evenly torque nuts
connecting rod cap and bearing. to 45 lb. ft. (61 N·m).
2. Inspect the bearing for evidence of wear and IMPORTANT: Do not turn the crankshaft with the
damage. Do not reinstall a worn or damaged gauging plastic installed.
bearing.
3. Wipe both upper and lower bearing shells and
crankpin clean of oil.
72891 72892
72893
e
a - Piston Pin Remover (J-24086-B)
b - Arched Base
c - Piston
d - Connecting Rod
e - Rod Support
72894
Cleaning and Inspection
PISTONS
NOTE: Cylinder bore and taper must be within
specifications before pistons can be considered for
re-use.
1. Clean varnish from piston skirts with a cleaning
solvent. DO NOT WIRE BRUSH ANY PART OF
PISTON. Clean ring grooves with a groove clean-
er and make sure oil ring holes are clean.
2. Inspect piston for cracked ring lands, skirts and
pin bosses, wavy worn ring lands, scuffed or
damaged skirts, and eroded areas at top of pis-
ton. Replace pistons which are damaged or show
signs of excessive wear.
72895
3. Inspect grooves for nicks and burrs that might
cause rings to hang up.
4. Measure piston skirt and check clearance as out-
lined under “Piston Selection.”
Reassembly
72897
a
a - Piston Pin Remover (J-24086-B)
72372
72377
a b
c c
72902
a - Pry Bar
b - Balance Shaft
c - Bearing Housing
72900
NOTE: When replacing balance shaft rear bearing,
a - Wedge place a cloth in valley to prevent any debris from en-
b - Driven Gear tering the crankcase.
c - Drive Gear
8. Balance shaft rear bearing can be replaced using
5. Unscrew stud and remove balance shaft drive balance shaft remover and installer tool in con-
gear on camshaft as shown. junction with bearing puller.
72901
a - Stud
b - Drive Gear
72903
72905
a - Alignment Marks
a
72907
Camshaft Bearings
Removal
Camshaft bearings can be replaced while engine is
disassembled for overhaul or without complete dis-
assembly. To replace bearings without complete dis-
assembly, remove camshaft and crankshaft, leaving
cylinder heads attached and pistons in place. Before
removing crankshaft, fasten connecting rods against
sides of engine so that they will not interfere while re-
placing camshaft bearings.
72908
1. With camshaft and crankshaft removed, drive
camshaft rear plug from cylinder block.
72909
Cylinder Block
72386
Measuring Cylinder Bore 4. When pistons are being fitted and honing is not
necessary, cylinder bores may be cleaned with a
8. Check cylinder head gasket surfaces for war- hot water and detergent wash. After cleaning,
page with a machinist’s straight-edge and a feel- swab cylinder bores several times with light en-
er gauge, as shown. Take measurements diago- gine oil and a clean cloth, then wipe with a clean
nally across surfaces (both ways) and straight dry cloth.
down center. If surfaces are warped more than
.003 in. (0.07 mm) in a 6 in. area or .007 in. (0.2 CYLINDER BORING
mm) overall, block must be resurfaced by an au-
tomotive machine shop. 1. Before using any type boring bar, file off top of cyl-
inder block to remove dirt or burrs. This is very im-
portant to prevent boring bar tilt, with result that
bored cylinder wall is not at right angles to crank-
shaft.
4. Permanently mark piston (for cylinder to which it b. Measure piston diameter at skirt across cen-
has been fitted) and proceed to hone cylinders ter line of piston pin as shown.
and fit remaining pistons.
72912