59341 Mercruiser COVER ASSEMBLY, CRANKCASE

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 9U-6198 Crankshaft Turning Tool 1
A(2) 9U-7336 Housing 1
5P-7305 Engine Turning Tool 1
B 136-4632 Timing Pin (Crankshaft) 1
268-1966 Adapter 1
C 370-8376 Capping Kit 1
D 1P-2320 Combination Puller 1
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tooling is used in the aperture for the electric starting motor.Start By:
If necessary, remove the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install" for the correct procedure.
If necessary, remove the fuel priming pump. Refer to Disassembly and Assembly, "Fuel Priming Pump - Remove" for the correct procedure.
If necessary, remove the crankcase breather (Filtered Breather). Refer to Disassembly and Assembly, "Crankcase Breather (Filtered Breather) - Remove" for the correct procedure.
Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure.
Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure.Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High-Pressure Fuel Lines" for safety information.Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Turn the fuel supply to the OFF position.
Turn the battery disconnect switch to the OFF position.
Illustration 1 g03388236
Remove plug (2) from the cylinder block. Remove O-ring seal (1) from the plug.
Use Tooling (A) to rotate the crankshaft so that number one piston is in the Top Dead Center Position on the compression stroke.
Install Tooling (B) through Hole (W) to lock the crankshaft.
Illustration 2 g03674811
Illustration 3 g06131558
Remove Tooling (B) from the crankshaft.
Use a suitable tool to hold crankshaft and loosen nut (5). Remove the nut and spring washer (6) (not shown).
Use Tooling (A) to rotate the crankshaft in a counter clockwise direction by 80 degrees. Refer to Illustration 2 for the correct positioning.Note: Rotating the crankshaft in a counter clockwise direction by 80 degrees will assist with the removal of the fuel injection pump.
Use Tooling (D) to remove gear (3) from fuel injection pump shaft (4).
Illustration 4 g06132010
Place a suitable container below fuel injection pump (19) to catch any fuel that might be spilled.
Clean fuel injection pump (19) and the area around the fuel injection pump. Ensure that the area is free from contamination before beginning disassembly.
Remove fuel injection lines (7) from fuel injection pump (19) and the fuel manifold. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove" for the correct procedure.Note: Discard the fuel injection lines.
Remove banjo bolt (8) from tube assembly (10). Remove bolt (12a) from clip for tube assembly. Remove sealing washers (9) (not shown). Use Tooling (C) to plug the tube assembly. Cap the ports in the fuel injection pump.
Disconnect harness assembly (11) from flow control valve (12).
Remove bolts (14) from bracket (15) for harness assembly (11).Note: The harness assembly should be repositioned to avoid obstructing removal of fuel injection pump (19).
Remove banjo bolt (16) from tube assembly (17). Remove sealing washers (13) (not shown). Use Tooling (C) to plug the tube assembly. Cap the ports in the fuel injection pump.
Disconnect the tube assembly from connection (18). Use Tooling (C) to plug the tube assembly. Cap the connection in the fuel injection pump.
Illustration 5 g06132014
Remove banjo bolt (21) from tube assembly (20). Remove sealing washers (22) (not shown). Position the tube assembly away from fuel injection pump (19). Use Tooling (C) to plug the tube assembly. Cap the connection in the fuel injection pump.
Remove banjo bolt (23)