Mercury MERCRUISER - Engine Mechanical 3

Engine Mechanical
Section 3A - Engine Disassembly
Table of Contents
Engine Block Codes...........................................................3A-2
Identification................................................................3A-2
Tools.................................................................................. 3A-3
Kent‑Moore................................................................. 3A-3
Precautions........................................................................ 3A-4
Torque Specifications........................................................ 3A-5
External Engine Components..................................... 3A-5
General Information........................................................... 3A-6
Repair Guidelines....................................................... 3A-6
Engine Rotation.......................................................... 3A-6
Crankcase Oil Dipstick Measurements.......................3A-6
Sterndrive Engine Mounts..................................................3A-7
Front Mounts...............................................................3A-7
Rear Mounts............................................................... 3A-7
Engine Components.......................................................... 3A-8
Cylinder Head and Rocker Cover Components .........3A-8
Timing Chain and Front Cover Components............ 3A-10
Crankshaft and Camshaft......................................... 3A-12
Piston and Connecting Rod ..................................... 3A-14
Intake Manifold and Fuel Rail (MPI)......................... 3A-16
Oil Pan and Oil Pump............................................... 3A-18
Remote Oil Filter.......................................................3A-20
Rocker Arm Cover........................................................... 3A-22
Removal....................................................................3A-22
Rocker Arms and Valve Pushrods................................... 3A-22
Removal....................................................................3A-22
Finding Top Dead Center (TDC)......................................3A-23
Method 1...................................................................3A-23
Method 2...................................................................3A-23
Intake Manifold Assembly................................................ 3A-24
Removal....................................................................3A-24
Hydraulic Valve Lifters..................................................... 3A-25
Exploded View.......................................................... 3A-25
Special Information................................................... 3A-25
Removal....................................................................3A-25
Oil Pump Drive.................................................................3A-26
Removal....................................................................3A-26
Flywheel and Housing......................................................3A-27
Flywheel Housing Removal...................................... 3A-27
Flywheel Removal.................................................... 3A-27
Oil Pan............................................................................. 3A-28
Removal....................................................................3A-28
Front Engine Cover..........................................................3A-29
Removal....................................................................3A-29
Timing Chain and Sprockets............................................3A-31
Removal....................................................................3A-31
Camshaft..........................................................................3A-32
Removal....................................................................3A-32
Cylinder Head.................................................................. 3A-33
Removal....................................................................3A-33
Valve Spring Assembly Exploded View.................... 3A-34
Valve Spring Assembly Removal..............................3A-35
Connecting Rod, Bearings, and Piston Assembly........... 3A-36
Exploded View.......................................................... 3A-36
Removal....................................................................3A-36
Disassembly............................................................. 3A-37
Rear Oil Seal....................................................................3A-38
Removal....................................................................3A-38
Oil Pump.......................................................................... 3A-39
Removal....................................................................3A-39
Disassembly............................................................. 3A-39
Crankshaft, Main Bearings, and Engine Block.................3A-40
Exploded View.......................................................... 3A-40
Removal....................................................................3A-40
Engine Block.............................................................3A-42
Engine Disassembly
90-8M0099748 eng DECEMBER 2015 © 2016 Mercury Marine Page 3A-1
3
A