5007661 EVINRUDE FUEL VAPOR SEPARATOR/ PUMP Assy

Crankshaft Grinding Specifications
The dimensions and finish for grinding crankshafts are as follows:Diameter (A) for connecting rod bearing journals is:.010 in. (0.25 mm) Undersize ... 2.7396 .0006 in.(69.586 0.015 mm).020 in. (0.51 mm) Undersize ... 2.7296 .0006 in.(69.332 0.015 mm).050 in. (1.27 mm) Undersize ... 2.6996 .0006 in.(68.570 0.015 mm)Surface finish must be 10 micro inches (0.25 micrometers) or less.Radius (B) must be .100 .010 in. (2.54 0.25 mm).Surface finish must be 63 micro inches (1.6 micrometers) or less.The radius must blend smoothly with the newly machined journals.
DIMENSIONS FOR GRINDING
A. Diameter of connecting rod bearing journals. B. Radius on connecting rod bearing journals. C. Width to grind journals for the connecting rods. D. Diameter of main bearing journals. E. Radius on main bearing journals. F. Width to grind journals for the main bearings.Width (C) is 2.314 .003 in. (58.77 0.08 mm)Diameter (D) for main bearing journals is:.010 in. (0.25 mm) Undersize ... 3.4895 .0006 in.(88.633 0.015 mm).020 in. (0.51 mm) Undersize ... 3.4795 .0006 in.(88.379 0.015 mm).050 in. (1.27 mm) Undersize ... 3.4495 .0006 in.(87.617 0.015 mm)Surface finish must be 10 micro inches (0.25 micrometers) or less.Radius (E) must be .095 .010 in. (2.41 0.25 mm).Surface finish must be 63 micro inches (1.6 micrometers) or less.The radius must blend smoothly with the newly machined journals.Width (F) is 1.258 .002 in. (31.95 0.05 mm) for number 4 main bearing journal. Surface finish on the thrust faces of the number 4 main must be 18 micro inches (0.45 micrometers) or less.Width (F) is 1.268 + .020 - .010 in. (32.21 + 0.51 - 0.25 mm) for number 2, 3 and 5 main bearing journals.There is no width (F) for number 1 main bearing journal.When grinding a crankshaft, no material can be removed from the crankshaft webs or counterweights.Crankshaft Gear Removal
Remove the gear using a 8B7548 Push Puller, 8B7551 Bearing Pulling Attachment, 8B7561 Step Plate, and 8H684 Ratchet Box Wrench.
PULLING CRANKSHAFT GEARThe 1P820 Hydraulic Puller Group can also be used to pull gear from crankshaft. Tools required are 1P820 Hydraulic Puller Group, 8B7551 Bearing Pulling Attachment, 8B7549 Puller Legs (two), 8B7561 Step Plate, 3H465 Plate (four), 1B4207 Nut (two) and 5P3100 Pump Group.
USING HYDRAULIC PULLERCrankshaft Gear Installation
1. Install the key in keyway of crankshaft. Remove all burrs from key and keyway inside of crankshaft gear.2. Heat gear to 500°F (260°C) maximum.3. Install gear on crankshaft with timing mark on gear facing front of crankshaft.Crankshaft Front Oil Seal Removal
Remove the crankshaft front pulley. Use the 1P3075 Puller Group to remove the crankshaft front oil seal.
REMOVING FRONT OIL SEAL (Typical Example)Remove Crankshaft Rear Seal And Wear Sleeve
Remove the crankshaft rear oil seal with the 1P3075 Puller Group.
REMOVING REAR OIL SEALInstall a 5P7338 Distorter Ring from the 5P7318 Wear Sleeve Distorter Group, in the rear seal bore. Install 5P7312 Distorter between distorter ring and wear sleeve. Turn the distorter until the edge of the tool makes a flat place (crease) in the wear sleeve. Do this in two or more places until the wear sleeve is loose. Remove the tools and wear sleeve.
REMOVING REAR WEAR SLEEVE (Typical Example)Install Crankshaft Rear Seal And Wear Sleeve
The crankshaft rear seal and wear sleeve must be installed at the same time. Clean the wear sleeve inside diameter and the crankshaft outside diameter and put 6V1541 Quick Cure Primer on the surfaces. Put 9S3265 Retaining Compound on the outside diameter of the crankshaft and the inside diameter of the wear sleeve. Install 5P290 Locator on the rear of the crankshaft. Put a sealer on the outer metal case of the seal.Put the wear sleeve and seal in position on the locater, with the outside diameter bevel on the wear sleeve away from the crankshaft. Be sure the lip of the seal is toward the engine. Put 5P7293 Installer in position on the locater. Put clean engine oil on the face of the nut and install it on the locater. Tighten the nut until the installer will no longer move.
INSTALLING CRANKSHAFT REAR SEAL AND WEAR SLEEVECrankshaft Front Oil Seal Installation
1. Put the seal over the short end of the 5P4194 Installer Assembly (A). Put a sealer on the outer diameter of the seal metal shell. The lip of the seal must be toward the inside of the engine.2. Put the seal and installer assembly (A) in position on the end of the crankshaft. Install bolt (1) and washer (2) that hold the crankshaft pulley in place. Tighten bolt (1) until the installer assembly (A) makes contact with the crankshaft gear. If a new wear surface for the front seal is needed, put 5P4230 Spacer between the seal and flange of the installer assembly.
INSTALLING FRONT OIL SEAL
1. Bolt. 2. Washer. A. 5P4194 Installer Assembly.3. Put engine oil on the lip of the seal before installing the pulley.Crankshaft Pulley Removal
1. Remove pulley retaining bolt and washer.2. Remove the pulley using a 5F7465 Puller Assembly, 8B7560 Step Plate, two 5M2894 Washers, and two S1571 Bolts.
PULLEY REMOVAL (Typical Example)Crankshaft Pulley Installation
1. Lubricate lip of crankshaft front oil seal and the sealing surface of crankshaft pulley with engine oil (SAE 30).2. To install pulley, start pulley on crankshaft. Put screw (4) from the 8B7548 Push Puller into the crankshaft until it bottoms out. Put crossbar (1) from the 8B7548 Push Puller onto screw (4). Install washer (2) and nut (3) onto screw (4). Hold screw (4) and turn nut (3) to press pully onto crankshaft.