806076 Mercruiser CAP

1. Remove three bolts (1) and locks. 2. Remove thrust plate (2) from behind the gear. 3. Install two 3/4"-16NF guide pins (3) in the front of the crankshaft as shown. Put a bar between the guide pins as shown. The bar is used to hold the crankshaft in position when nut (4) is removed.4. Remove nut (4) and the lock.5. Install nut (4) back on the accessory drive shaft until it is even with the end of the shaft. 6. Use tooling (A) to remove gear (5) from the accessory drive shaft. Remove the nut and the gear from the shaft. 7. Remove key (6) from the shaft. 8. Pull accessory drive shaft (7) out of the rear of the cylinder block. 9. Remove gear (8) from the accessory drive shaft with tooling (B). 10. Remove two bolts (9) and locks.11. Remove cage assembly (11) from the timing gear housing assembly.12. Remove two bushings (10) from the cage assembly with tooling (C). 13. Remove the three bearings from the cylinder block with tooling (D).Install Accessory Drive
1. Install the three bearings for the accessory drive shaft in the cylinder block with tooling (A).2. Put clean engine oil on the bearing surfaces. 3. Install the two bushings in the cage assembly with tooling (B). Install the bushings even with the outside surfaces of the cage assembly.
Make sure the oil hole in the cage assembly is not covered after the two bushings are installed.
4. Put cage assembly (1) in position in the timing gear housing assembly. Make sure the oil hole in the cage assembly is toward the top of the cylinder block. Install the two locks and bolts that hold the cage assembly in position. 5. Heat gear (2) to a maximum temperature of 600°F (315°C). Install the gear on the accessory drive shaft until it is even with the end of the shaft. 6. Install accessory drive shaft (3) and the gear in the cylinder block. Make sure the mark on the accessory drive gear is in alignment with the mark on the crankshaft. 7. Hold a string from the center of the accessory drive shaft to the center of the crankshaft as shown. Make sure the mark on the accessory drive gear is in alignment with the mark on the crankshaft. The marks must be in a straight line with the center of the accessory drive shaft and the center of the crankshaft. If necessary, pull the accessory drive shaft out of the cylinder block and move it to another position for the correct alignment. Also turn the crankshaft if necessary for the correct alignment.8. Install the key in the front of the accessory drive shaft. 9. Install gear (4) on the accessory drive shaft. Install the lock and nut (5). Tighten the nut to a torque of 250 10 lb.ft. (339.0 3.6 N m). 10. Install thrust plate (6) behind the gear. Install the three locks and bolts that hold it.end by: a) install timing gearsb) install crankshaft front seal