Mercury MerCruiser Service Manual page 203

Section 3B - Engine Inspection and Assembly
Table of Contents
General Specifications....................................................... 3B-2
Engine Specifications.........................................................3B-3
Cylinder Head............................................................. 3B-3
Cylinder Bore.............................................................. 3B-3
Oil Pump..................................................................... 3B-3
Piston Bore Clearance................................................3B-3
Piston Rings................................................................3B-3
Piston Pin....................................................................3B-4
Crankshaft.................................................................. 3B-4
Connecting Rod.......................................................... 3B-4
Valve...........................................................................3B-4
Camshaft.................................................................... 3B-6
Timing Chain...............................................................3B-6
Flywheel......................................................................3B-6
Engine Block...................................................................... 3B-6
Clean and Inspect.......................................................3B-6
Cylinder Reconditioning..............................................3B-7
Cylinder Boring........................................................... 3B-8
Cylinder Honing.......................................................... 3B-8
Piston Selection.......................................................... 3B-8
Camshaft Bearings..................................................... 3B-9
Engine Block Plugs...................................................3B-12
Crankshaft and Pistons....................................................3B-14
Cleaning....................................................................3B-14
Main Bearing Inspection........................................... 3B-15
Crankshaft Installation.............................................. 3B-17
Main Bearing Clearance, Plastigauge Method......... 3B-20
Crankshaft End Play................................................. 3B-21
Preliminary Inspection.............................................. 3B-22
Piston Inspection...................................................... 3B-22
Piston Ring Gap Inspection...................................... 3B-24
Assembly.................................................................. 3B-24
Piston/Connecting Rod Assembly............................ 3B-25
Piston and Rod Installation....................................... 3B-25
Connecting Rod Bearing Clearance, Micrometer
Method.................................................................. 3B-29
Connecting Rod Bearing Clearance, Plastigauge
Method.................................................................. 3B-30
Oil Pump.......................................................................... 3B-32
Inspection................................................................. 3B-32
Installation.................................................................3B-32
Camshaft .........................................................................3B-33
Inspection................................................................. 3B-33
Installation.................................................................3B-34
Timing Chain....................................................................3B-35
Inspection................................................................. 3B-35
90-8M0099748 eng DECEMBER 2015
Engine Mechanical
Assembly.................................................................. 3B-35
Checking Timing Chain Deflection............................3B-36
Installation.................................................................3B-37
Crankcase Front Cover....................................................3B-37
Installation.................................................................3B-37
Rear Seal Installation................................................3B-38
Oil Pan............................................................................. 3B-39
Inspection................................................................. 3B-39
Installation.................................................................3B-40
Cylinder Head.................................................................. 3B-43
Core Plug Installation................................................3B-43
Inspection................................................................. 3B-44
Repair....................................................................... 3B-47
Cylinder Head Reassembly...................................... 3B-49
Installation.................................................................3B-51
Lifters............................................................................... 3B-54
Inspection................................................................. 3B-54
Lifter Installation........................................................3B-55
Oil Pump Drive.................................................................3B-55
Inspection................................................................. 3B-55
Installation.................................................................3B-55
Rocker Arms and Pushrods............................................. 3B-56
Inspection................................................................. 3B-56
Installation.................................................................3B-57
Intake Manifold Assembly................................................ 3B-59
Intake Manifold......................................................... 3B-59
Installation.................................................................3B-59
Rocker Arm Cover........................................................... 3B-62
Installation.................................................................3B-62
Flywheel...........................................................................3B-62
Cleaning and Inspection........................................... 3B-62
Installation.................................................................3B-62
Flywheel Housing.............................................................3B-65
Cleaning....................................................................3B-65
Inspection................................................................. 3B-65
Installation.................................................................3B-65
Oil Lines........................................................................... 3B-66
Crankcase Front Cover Oil Seal (Without Removing Front
Cover)...........................................................................3B-67
Removal....................................................................3B-67
Installation.................................................................3B-67
Main Bearings, Without Crankshaft Removed................. 3B-68
Installation.................................................................3B-68
Valves and Seals (Without Removing Head)...................3B-69
Valve Spring Assembly Exploded View.................... 3B-69
Valve Spring Assembly Removal..............................3B-69
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Engine Inspection and Assembly
Page 3B-1
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