9565A 1 Mercruiser CARBURETOR ASSEMBLY

Removal
Invert engine.
Fig. 1-Engine InvertedRemove oil pan (1, Fig. 1) (Group 0407).Remove engine timing gear cover (2) (Group 0402).Remove flywheel and flywheel housing (Group 0433).Crankshaft End Play
Fig. 2-Crankshaft End PlayPosition a dial indicator against end of crankshaft (Fig. 2). IMPORTANT: Do not apply too much pressure with pry bar as this could damage bearings.Using pry bar, carefully move crankshaft rearward.Zero the dial indicator.Using pry bar, carefully move crankshaft forward.Read dial indicator.
Fig. 3-Crankshaft End PlaySpecifications are as follows: New crankshaft end play ... 0.002 to 0.008 inch(0.05 to 0.20 mm)Maximum crankshaft end play ... 0.015 inch(0.38 mm)
Fig. 4-Main Bearing Cap PositionsRemove connecting rod caps (Fig. 4). Push pistons and connecting rods toward the cylinder head.Check main bearing caps for identifying numbers. If there are no numbers, stamp corresponding numbers in one oil pan rail and in main bearing cap. Stamp the number in each main bearing cap off center to the same side as the number in the oil pan rail. This will assure correct indexing of main bearing caps during installation.Remove main bearing caps.Lift crankshaft from cylinder block.Remove main bearing inserts from cylinder block and from main bearing caps.Repair
Measure crankshaft main journal to main bearing clearance.
Fig. 5-Main Bearing ClearanceMain bearing journal O.D. (new) (1, Fig. 5) ... 3.123 to 3.124 inch(79.32 to 79.35 mm)Assembled Main bearing I.D. (new) (2) ... 3.126 to 3.128 inch(79.39 to 79.45 mm)Main bearing clearance (new) (3) ... 0.0016 to 0.0046 inch(0.041 to 0.117 mm)Main bearing clearance (maximum) ... 0.006 inch(0.15 mm)Main bearing bore I.D. (4) ... 3.325 to 3.326 inch(84.46 to 84.48 mm)Measure crankshaft main journal taper and roundness.
Fig. 6-Main Bearing MeasurementJournal taper (maximum) (1, Fig. 6) ... 0.001 inch per 1.00 inch(0.03 mm per 25.4 mm)Journal out-of-round (maximum) (2, Fig. 6) ... 0.003 inch(0.08 mm)If wear is even, but out of specifications, dress crankshaft main journals and select proper undersize bearing inserts.If journals are out-of-round or tapered, grind crankshaft and select proper undersize bearing inserts.If crankshaft end play is excessive, replace worn thrust bearings or grind crankshaft thrust surfaces and select proper oversize thrust bearing.Installation
Fig. 7-Main Bearing Insert InstallationPosition bearing inserts in cylinder block and main bearing caps with the tang on the insert engaged in the slot in the cylinder block and main bearing caps (Fig. 7).Apply a coat of clean engine oil to the bearing surface of the inserts.Position crankshaft in cylinder block. Tangs on main bearing halves in main bearing caps must be positioned to the same side of the crankshaft as the tangs on main bearing halves in cylinder block.
Fig. 8-Main Bearing Cap PositionsInstall main bearing caps with numbers (1, Fig. 8) corresponding to numbers in oil pan rail (2). If there is no arrow (3) machined on main bearing cap, install cap with number to same side as numbers in oil pan rail. If there is an arrow machined on main bearing cap, arrow must point toward camshaft side.Dip main bearing cap screws in clean engine oil and position them in the main bearing caps. IMPORTANT: Do not use pneumatic wrench to install main bearing cap screws.Before tightening cap screws on main bearing caps, align upper and lower thrust flanges on main thrust bearings. Using a soft-face hammer, tap crankshaft to the rear and then to the front to line up thrust bearing flanges.Rotate crankshaft by hand. Crankshaft should rotate with little effort.
Fig. 9-Main Bearing Cap ScrewTighten main bearing cap screws (Fig. 9)Main bearing cap screw torque ... 85 lb-ft(115 N m) (12 kg-m)Turn crankshaft by hand. If it does not turn easily, disassemble parts and determine the cause.Pull piston and connecting rods into position against the crankshaft.Install connecting rod caps (Group 0403).Install engine front plate (Group 0404).Install camshaft (Group 0402).Install timing gear train (Group 0402).Install timing gear cover (Group 0402).Install vibration damper (Group 0401).Install fan belt and alternator belt (Group 0429).Install flywheel housing (Group 0433).Install flywheel (Group 0433).Install oil pan (Group 0407).Install pushrods and rocker arm assembly (Group 0402).Install rocker arm cover (Group 0402).Install fuel transfer pump (Group 0421).Crankshaft Gear
Removal
Remove crankshaft from engine (Group 0401).
Fig. 10-Crankshaft Gear RemovalUse knife-edge puller (1, Fig. 10) to remove crankshaft gear (2) from crankshaft.Repair
Inspect crankshaft gear for worn, cracked, or broken teeth. Replace damaged gear.
Plan safe handling procedure to avoid burns.
IMPORTANT: Do not use torch or small concentrated flames to heat gear. Do not overheat gear.Heat gear to 360°F (182°C).
Fig. 11-JDH-7 DriverWith Woodruff key in place, drive gear onto crankshaft with JDH-7 Driver (Fig. 11).Install crankshaft in engine (Group 0401).Crankshaft Front Wear Ring (used on 6-329D, 6-359D, 6-359T, 6-414D, and 6-414T)
Removal
Remove timing gear cover (Group 0402).
Fig. 12-Crankshaft Front Wear RingSlide wear ring off of crankshaft (Fig. 12).InstallationSlide wear ring onto crankshaft.Install timing gear cover (Group 0402).Install vibration damper (Group 0401).Crankshaft Front Oil Seal
Fig. 13-Oil SealSee Group 0402 to service crankshaft front oil seal.Crankshaft Rear Oil Seal And Wear Ring
Fig. 14-Wear RingRemoval
Remove flywheel (Group 0433).Remove seal with JDG-22 Seal Remover.Repair
IMPORTANT: DO NOT scratch crankshaft surface.Cut wear ring off crankshaft.Look for nicks or burrs on wear ring surface. If there is a nick or burr, use FINE emery cloth to remove it.Installation
Use either JDE-140 or KCD-10002 Rear Seal and Wear Ring Installer.
Fig. 15-Pilot PlateAttach guide plate (1) with cap screw (2). IMPORTANT: Use only enough sealant to fill nicked or scratched area.Put a very thin film of T43513 John Deere LOCTITE® Thread Lock and Sealer (high strength), PT502 John Deere Gasket Maker or an equivalent selanat on the wear ring surface of the crankshaft.
Fig. 16-Wear Ring And SealCheck to be sure chamfer on wear ring inside diameter (1) and open side of the seal (2) are toward the same side.
Fig. 17-Wear Ring And Seal On Guide PlateInstall seal and wear ring on guide plate with open side of seal toward engine.
Fig. 18-Install Wear Ring And SealAttach driver and thru