0115006 EVINRUDE BEARING, Forward gear

Cylinder Block
Remove intake manifold (Group 0414).Remove exhaust manifold (Group 0410).Remove fuel injection pump and fuel injection nozzles (Group 0413).Remove starting motor (Group 0422).Remove alternator (Group 1672) and fan belts.Remove fuel filter assembly (Group 0402).Remove rocker arm cover, rocker arm assembly and push rods (Group 0402).Remove cylinder head and water manifold as one piece (Group 0409).
Fig. 1-Location of Liners in Cylinder BlockDo not rotate crankshaft with cylinder head removed unless cylinder liners are bolted down (Fig. 1). Use short cap screws and large flat washers to hold cylinder liners in place.Remove tappets from their bores (Group 0402).Remove oil filter, oil filter housing, and dipstick (Group 0407) and engine oil cooler (Group 0419).Remove engine oil pan and oil pump (Group 0407).Remove crankshaft pulley and timing gear cover (Group 0402).Remove camshaft (Group 0402).Remove the water pump (Group 0417).Remove flywheel and flywheel housing (Group 0433).Remove pistons and connecting rods (Group 0403).
Fig. 2-Piston Cooling OrificesRemove crankshaft (Group 0401) and piston cooling orifices (Fig. 2).Cylinder Liner
Remove the cylinder head (Group 0409) and connecting rods and pistons (Group 0403).Measure cylinder liner protrusion (Group 0404 - Installation).
Fig. 3-Cylinder Liner FrontUsing a center punch, mark front of cylinder liner on top of "fire dam" (Fig. 3).
Fig. 4-D-01062AA oR D01073AA PullerUse D01062AA, D01073AA Puller (Fig. 4) or KCD-10001 Puller (Fig. 4A) to remove cylinder liners, if necessary.Remove cylinder packings from cylinder liner bore.Remove cylinder liners using KDC-10001 Puller as follows:
Fig. 5-KCD-10001 PullerPre-assemble pressure block KCD 10001-3 on spindle as shown in (Fig. 5) and tighten lock nuts KCD 10001-4.Guide special tool at any angle into cylinder liner.Secure bridge piece KCD 10001-2 to cylinder block, using two cylinder head cap screws.Force cylinder liner out of cylinder block by turning spindle KCD 10001-1.Repair
Cylinder Block
Inspect the cylinder block for damage. If block is useable, scrape all gasket material from the cylinder block.Thoroughly clean the cylinder block.Refer to "Basic Engine" in FOS Manual-ENGINES for additional information on cleaning cylinder blocks.Make sure all passages and crevices are cleaned of sludge, rust, and grease. Be sure all coolant passages are cleaned of lime deposits and scale. Use a wire brush or emery cloth to carefully remove rust and scale from cylinder liner bores. Make certain there are no nicks or burrs in areas where cylinder liner packings will seat.The cylinder block may be tested for cracks or leaks.Refer to "Basic Engine" in FOS Manual-ENGINES for additional information on testing cylinder blocks.Replace dowel pins and studs as necessary. Use T43515 John Deere LOCTITE, or equivalent, on dowel pins.Cylinder Liner
Use same piston which was removed from cylinder liner being checked.Use the following procedure to check a liner:
Fig. 6-Piston to Liner Clearance1. Put piston in liner with piston "front" and liner "front" aligned. Move piston down until bottom edge of piston skirt is 1.00 in. (25.4 mm) (1, Fig. 6) above bottom of liner.Use a feeler gauge to measure distance (2) between piston skirt and liner 90° to piston pin bore. Record the measured distance (2).Piston to cylinder liner clearance for new parts is: 2. Turn piston 90° in liner. Use a feeler gauge to measure distance between piston skirt and liner 90° to piston pin bore. Record the measured distance.The difference between the distance measured in Step 1 and the distance in Step 2 is the distance the liner is out of round at the bottom of the liner.
Fig. 7-Piston to Liner Clearance3. Pull piston out of liner. Put piston in liner up-side down with piston "front" and liner "front" aligned. Move piston so bottom edge of piston skirt is 1.00 in. (25.4 mm) (1, Fig. 7) below top of liner.Use a feeler gauge to measure distance (2) between piston skirt and liner at 90° to piston pin bore. Record the measured distance (2).4. Turn piston 90° in liner. Use a feeler gauge to measure distance between piston skirt and liner 90° to piston pin bore. Record the measured distance.The difference between the distance measured in Step 3 and the distance measured in Step 4 is the distance the liner is out of round at the top of the liner.If liner is out of round more than 0.002 in. (0.05 mm), at top or bottom, install a new one.5. Find difference between distance measured in Step 1 and distance measured in Step 3. This is the distance the liner is tapered.If liner is tapered more than 0.002 in. (0.05 mm), install a new one.Use a wire brush to carefully remove all rust and scale from the outside of the cylinder liners. Make certain there are no nicks or burrs in the areas where the packings will seat.After removing the rust and scale from the cylinder liners wash thoroughly with solvent and dry them.
Fig. 8-D17004BR Cylinder BrushUse D17004BR Cylinder Brush (Fig. 8) to deglaze each cylinder liner. Match the existing cross hatch pattern when deglazing.Refer to "Basic Engine" in FOS Manual-ENGINES for additional information on deglazing cylinder liners.Immediately after deglazing, clean cylinder liner bore with waterless hand cleaner or soap. Rinse cylinder liner bores with clean water until rinse water is clear. Dry liners with clean towels. Wipe bore with clean engine oil. IMPORTANT: Solvents will not remove honing residue.Recheck liner-to-piston skirt clearance. See Group 0403 for piston repair.Piston Cooling Orifices
Inspect for damage or clogging.
Fig. 9-Piston Cooling OrificeIf a piston cooling orifice (2, Fig. 9) is clogged, use a soft wire (1) to push material out of hole.If an orifice is damaged install a new one.Installation
Fig. 10-Piston Cooling OrificesInstall piston cooling orifices (Fig. 10) and tighten to 85 to 110 lb-in. (9.6 to 12.4 N m) torque.Install the crankshaft (Group 0401), flywheel, and flywheel housing (Group 0433).When installing a new cylinder liner in block, first place liner in liner bore without cylinder liner packings. Use short cap screws and large flat washers to hold liners in place.
Fig. 11-Liner Flange HeightUse a dial indicator gauge to check the height of the liner flange (1, Fig. 11) above the top of the cylinder block (3). The height should be 0.001 to 0.004 in. (0.03 to 0.10 mm) (2, Fig.