1
2
3
4
5
6
7
8
9
- Distributor Cap
- Vent
- Gasket
Reassembly
1.
Lubricate shaft with engine oil. Install E-clip (if
removed) on shaft in housing.
- Rotor
- Senor Wheel
- Screws (5)
- E-Clip
- Shaft
- Screws (2)
2.
Install washer on shaft. Install original gear; slide
onto shaft and install roll pin.
IMPORTANT: Hole may be offset and gear will
only fit in one direction.
10-
Lockwashers (2)
11
12-
13-
- Sensor
Upper Bushing
Ignition Module , If Equipped (Apply Thermal-
conductive Grease)
Screws (2)
Distributor Housing
Lockwasher
Nut
Lower Bushing
Gasket
3.
If installing a new gear, the gear will come drilled
on one side. Slide gear onto shaft; align hole in
gear with hole in shaft. Using these holes as
guides, drill through other side of gear with a
14-
3/16
in. carbide tripped drill.
15-
16-
17-
18-
19-
20-
21-
22-
IMPORTANT: If a new gear has only a dimple, you
will have to drill through one side of the gear be-
fore you slide gear onto shaft. In most cases it is
recommended to have a machine shop complete
the drilling operation for new gear installation.
Washer
Gear
Roll Pin
Disassembly
a
NOTICE
d
Refer to exploded view preceding for parts
identification during disassembly and reas-
sembly.
b
1.
Remove rotor, sensor wheel, sensor, and ignition
module (if mounted on distributor), as previously
outlined.
2.
3.
Remove roll pin, washer and driven gear from
distributor shaft.
c
Check for side play between shaft and distributor
housing bushings. Maximum side play is .002 in.
72735
(0.05
mm).
a - Drill Press
b - 3/16 in. Carbide Tip Drill
c - V-Block
4.
Remove shaft from housing and check shaft for
being bent with a dial indicator and V-blocks.
Maximum runout is .002 in. (0.5 mm).
d - New Gear
4.
5.
Install sensor, sensor wheel, rotor, and ignition
module (if mounted on distributor), as previously
outlined.
Install distributor as outlined in “Distributor Instal-
lation.”
Index
90-823224--2 796
IGNITION SYSTEM - 4B-11
| 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