803610 Mercruiser COUPLER ASSEMBLY

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     8S-2241     Camshaft Bearing Tool Group     1    
8S-8293 Extension     1    
5P-1667 Tube     1    Start By:
Remove the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Remove and Install".
Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and Install".
Remove the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Remove".
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Illustration 1 g00569925
Remove the rear camshaft bearing with Tool (A) .
Remove the remainder of the camshaft bearings with Tool (A) through the rear of the engine block. Start from the rear of the cylinder block and move toward the front.Installation Procedure
Table 2
Required Tools    
Tool    Part Number    Part Description    Qty    
A     8S-2241     Camshaft Bearing Tool Group     1    
8S-8293 Extension     1    
5P-1667 Tube     1    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Ensure that the inside of the cylinder block is clean. Inspect the camshaft bore for metal burrs. Put a thin film of clean engine oil on the inside of the camshaft bearing bores and on each camshaft bearing prior to installation.Note: Two different camshaft bearings are used. Install the wider camshaft bearings in the front and rear camshaft bores. Install the narrow camshaft bearings in the inner bores.
Illustration 2 g00570127
Install all the camshaft bearings with Tool (A) so that the oil hole in the camshaft bearing is in a horizontal position. Installation angle (1) is 90 15°.
Install the camshaft bearings with Tool (A) on the front side of the engine. Start the bearing that is being installed from the rear of each bore. Pull the bearing into the bore with Tool (A). Use the following procedure for achieving the proper installation depth for the bearings.
Illustration 3 g00583232
Install the rear camshaft bearing. Pull the bearing into the bore until the front face of the bearing is flush with the front face of bore (2).
Install the narrow internal camshaft bearings. Start at the rear of the engine and work forward. Pull each bearing into the bore until the front face of the bearing is flush with the front face of the bore.
Illustration 4 g00569930
Measure the depth of the front camshaft bearing.
Install the front camshaft bearing with Tool (A) until the bearing is at the specified depth. the depth is measured from the front of the engine block.The front camshaft bearing for the 3412E should be 7.4 0.5 mm (0.29 0.02 inch) from the front face of the engine block.The front camshaft bearing for the 3408E should be 4.6 0.5 mm (0.18 0.02 inch) from the front face of the engine block.Note: Refer to Specifications, "Camshaft Bearings" for more information about camshaft bearings.End By:
Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and Install".
Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Remove and Install".
Install the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Install".