Crankshaft
Cleaning and Inspection
1.
Wash crankshaft in solvent and dry with com-
pressed air.
Removal
2.
Measure main bearing journals and crankpin di-
mensions with a micrometer for out-of-round, ta-
per or undersize (see “Specifications”).
1.
2.
3.
Remove engine from boat.
Drain crankcase oil.
Remove as outlined:
a. Starter.
3.
4.
Check crankshaft for runout (by supporting at
front and rear main bearings journals in V-blocks)
and check at front and rear intermediate journals
with a dial indicator (see “Specifications”).
b. Flywheel housing.
c. Drive coupler/plate and flywheel.
d. Belts.
Replace or recondition crankshaft if not within
specifications.
e. Water pump.
Installation
f.
Crankshaft pulley and torsional damper.
1.
If a new crankshaft is being installed, proceed as
follows:
g. Spark plugs.
h. Oil pan and dipstick tube.
a. Remove timing sprocket or gear from old
crankshaft and reinstall on new crankshaft as
outlined.
i.
j.
Baffle and oil pump.
Timing chain/gear cover.
b. Onmodelswithdriveshaftextension,ifoldpi-
lotbushingistobereused,bushingcanbere-
moved without damage by filling pilot bushing
cavity with grease, then inserting an old
transmission input shaft in bore of bushing
and hitting it with a hammer. This will create
hydraulic pressure in pilot bushing cavity
which should force bushing out.
4.
Turn crankshaft to align timing mark with cam-
shaft mark.
5.
6.
Remove camshaft sprocket or gear.
Remove rear main seal.
IMPORTANT: Inspect bearing caps for orienta-
tion marks prior to removal. If no markings exist,
make suitable marks before disassembly so that
they can be reinstalled in their original locations.
IMPORTANT: Be sure that all bearings and crank-
shaft journals are clean.
7.
Make sure all bearing caps (main and connecting
rods) are marked so they can be reinstalled in
their original locations.
2.
Install main bearings in engine block as follows.
a
8.
Remove connecting rod bearing caps, then push
piston and rod assemblies toward heads.
b
9.
Remove main bearing caps and carefully lift
crankshaft out of cylinder block.
10.
If new main and/or connecting rod bearings are
to be installed, remove main bearing inserts from
cylinder block and bearing caps, and/or connect-
ing rod bearing inserts from connecting rod and
caps. Install new bearings following procedures
outlined.
c
72359
Main Bearing Inserts
a - Lower Bearing Insert (Install In Cap)
b - Upper Bearing Insert (Install In Block)
c - Oil Groove
Index
3A-54 - 454 C.I.D. (7.4L) / 502 C.I.D. (8.2L)
90-823224--2 796
| Categories | Mercury MerCruiser Manuals |
|---|---|
| Tags | Mercury MerCruiser 454 CID, Mercury MerCruiser 502 CID |
| Model Year | 1993, 1994, 1995, 1996, 1997 |
| Download File |
|
| Document File Type | |
| Copyright | Attribution Non-commercial |
(4 votes, average: 4.5 out of 5)
Marine readers have rated 1993 1997 Mercury-MerCruiser GM V8 454 CID 7.4L and 502 CID 8.2L Marine Engines Service Manual Number 16 4.5 out of 5.0 based on 4 product reviews. Hugely helpful service manual! Perfect. Thank you!
Manuals are all Important for Technician
This book is invaluable if you do your own repairs. Great book.
Could not find a copy until a search brought me here.
Excellent print.
Thank you