801761165 Mercruiser BANJO BOLT

Table 1
Required Tools
Part Number Part Name Quantity
214-7340 Reverse Ratchet 1
9S-9082 Engine Turning Tool 1
5P-7305 Engine Turning Tool 1
136-4632 Timing Pin 1
139-7063 Timing Pin Adapter 1
139-7064 Timing Pin Adapter 1
Illustration 1 g00780199
Typical Example
(1) Flywheel Housing (2) Timing Hole Plug (3) Cover Bolt (4) Cover
Remove two bolts (3) and remove cover (4) from flywheel housing (1) in order to open the turning hole.
Thread the 136-4632 Timing Pin with the proper Timing Pin Adapter into the timing hole. The timing hole is located approximately 127 to 152 mm (5.0 to 6.0 inch) above the turning hole for the engine turning tool in the flywheel housing. Use the 9S-9082 Engine Turning Tool and a 214-7340 Reverse Ratchet to turn the engine flywheel. Turn the flywheel in the direction of engine rotation. The direction of engine rotation is counterclockwise, as the engine is viewed from the flywheel end. Turn the flywheel until the Timing Pin engages with the hole in the flywheel. Note: 5P-7305 Engine Turning Tool may be used in certain applications if the 9S-9082 Engine Turning Tool will not fit the flywheel housing.Note: If the flywheel is turned beyond the point of engagement, the flywheel must be turned in the direction that is reverse of normal engine rotation. Turn the flywheel by approximately 30 degrees. Then turn the flywheel in the direction of normal rotation until the Timing Pin engages with the hole in the flywheel. This procedure removes the play from the gears when the No. 1 piston is at the top center position.
Remove the front valve mechanism cover from the engine.
The inlet and exhaust valves for the No. 1 cylinder are fully closed if No. 1 piston is on the compression stroke and the rocker arms can be moved by hand. If the rocker arms cannot be moved and the valves are slightly open, the No. 1 piston is on the exhaust stroke. Note: When the actual stroke position is identified, and the other stroke position is needed, remove the Timing Pin from the hole in the flywheel. Then turn the flywheel by 360 degrees in the direction of normal engine rotation and reinstall the Timing Pin into the hole in the flywheel.Note: Never turn the engine by the crankshaft vibration damper. The crankshaft vibration damper is a precision part. Major engine failure may be caused by damage to the crankshaft vibration damper.Procedure for Engines that have a Rear Power Take-Off
Table 2
Required Tools
Part Number Part Name Quantity
9U-6639 Ratchet Wrench 1
208-0888 Engine Turning Tool 1
208-9387 Pin 1
208-9388 Adapter 1
Illustration 2 g00837908
Typical Rear Power Take-Off
(1) Cover
(2) Bolt
(3) Flywheel housing
(4) Timing hole
Remove two bolts (2) in order to remove cover (1) from flywheel housing (3). This will allow you to use 208-0888 Engine Turning Tool to rotate the engine.
Remove the plug in the timing hole (4). Place the 208-9387 Pin through the hole of the 208-9388 Adapter. This will allow you to install the tool without removing the ECM. Thread the 208-9387 Adapter into the flywheel housing. The timing hole is located approximately 127 to 152 mm (5.0 to 6.0 inch) above the bore for the starter motor in the flywheel housing.
Install the 208-0888 Engine Turning Tool into the splines of the hydraulic pump drive gear in flywheel housing (3). Turn the engine in the direction of normal rotation. Rotation of the engine is viewed from the flywheel housing. Rotation of the engine is counterclockwise. The 208-0888 Engine Turning Tool needs to rotate the same direction as the crankshaft. Rotate the engine with the 208-0888 Engine Turning Tool and the 9U-6639 Ratchet Wrench. Note: If the flywheel is turned beyond the point of engagement, the flywheel must be turned in the direction that is reverse of normal engine rotation. Turn the flywheel by approximately 30 degrees. Then turn the flywheel in the direction of normal rotation until the Timing Pin engages with the hole in the flywheel. This procedure removes the play from the gears when the No. 1 piston is at the top center position.
Remove the front valve mechanism cover from the engine.
The inlet and exhaust valves for the No. 1 cylinder are fully closed if No. 1 piston is on the compression stroke and the rocker arms can be moved by hand. If the rocker arms cannot be moved and the valves are slightly open, the No. 1 piston is on the exhaust stroke. Note: When the actual stroke position is identified, and the other stroke position is needed, remove the Timing Pin from the hole in the flywheel. Then turn the flywheel by 360 degrees in the direction of normal engine rotation and reinstall the Timing Pin into the hole in the flywheel.Note: Never turn the engine by the crankshaft vibration damper. The crankshaft vibration damper is a precision part. Major engine failure may be caused by damage to the crankshaft vibration damper.Checking and Calibrating the Electronic Injection Timing With the Electronic Service Tool
Refer to Troubleshooting, "Engine Speed/Timing Sensor - Calibrate" for the proper procedure to calibrate the electronic injection timing.