Removal; Cleaning; Inspection - Mercury MerCruiser D2.8L D-Tronic Service Manual

ENGINE MECHANICAL

Removal

1. If equipped, remove power steering pump and vacuum pump belt.
2. Remove alternator belt and upper alternator bracket screw, spacer and hardware from
timing gear cover.
When removing seawater hoses or seawater pump, close seacock, if equipped. If
boat is not equipped with a seacock, remove and plug seawater inlet hose to
prevent a siphoning action that may occur, allowing seawater to flow from the drain
holes or removed hoses and enter boat.
3. Refer to SECTION 6A - Seawater Cooling System, and remove seawater pump inlet
hose and outlet hose. Then, remove seawater pump.
4. Install flywheel holding tool 91-801333506.
5. Remove six allen-head bolts and remove crankshaft vibration damper.
6. Using a suitable socket remove the large crankshaft pulley nut.
7. Using Puller 91-801333507, remove crankshaft pulley
8. Remove fasteners, including one at alternator bracket, and remove timing cover. Note
size and position of fasteners for reassembly.

Cleaning

1. Remove old gasket material from block and timing cover. Be careful not to gouge or nick
flanges.
2. Wash all parts in cleaning solvent and dry with compressed air.
3. If oil seal is removed for replacement, clean the seating surface in the cover.

Inspection

1. Inspect parts for cracks or damage.
2. Check oil seal for wear or damage. Using a suitable tool remove and replace oil seal if
needed.
NOTE: Bore in timing cover for oil seal must not be worn. Oil seal must fit securely in cover.
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CAUTION
SERVICE MANUAL NUMBER 22
90-860074--1 FEBRUARY 2002