59341A 1 Mercruiser COVER ASSEMBLY

*If the flywheel housing is to be removed so the timing gears and plate can be removed, do Step 1 through 10 before these start bys are completed. These steps will put the engine in correct time.1. Remove plate (1) from the left side of the flywheel housing. Bolt (2) is also the timing bolt for the flywheel. Some engines do not have the nut welded on the retainer. Use Step 2 on these engines.2. There are two ways the engine can be turned. The first way is as follows: a) Remove bolts (4) that hold pinion (3) and spacer (5) to the flywheel housing.b) Install pinion (3) in the flywheel housing. Use a 1/2" ratchet and turn the engine. 3. The second way is as follows: a) The retainer (6) that holds the vibration damper and hub on the crankshaft has a 1 1/8" nut welded to it.b) Use a 1 1/8" socket and turn the engine. This will take two persons to do this procedure. 4. Turn the engine clockwise (as seen from the flywheel) approximately 30° to remove the play in the timing gears. Turn the engine counterclockwise (as seen from the flywheel) until the threaded hole in the flywheel is in alignment with the hole in the flywheel housing and bolt (2) can be installed in the flywheel. The No. 1 piston is at top center compression stroke.5. The intake and exhaust valves for No. 1 cylinder on the right side of the engine must be free to move by hand. If not, it will be necessary to turn the engine counterclockwise (as seen from the flywheel) 360° more and install bolt (2) again. If the hole in the flywheel is turned beyond the hole in the flywheel housing, turn the engine clockwise (as seen from the flywheel) a minimum of 30° before the engine is turned counterclockwise (as seen from the flywheel) to install bolt (2).6. Disconnect the governor control linkage from the governor lever. 7. Remove the speed limiter access plug from the governor. Loosely install 9S8519 Plug (7) [part of tooling (A)]. Install 9S8521 Rod (8) [part of tooling (A)] and push in the speed limiter plug. Tighten plug (7). This will let the governor control lever move through its complete length of travel. 8. Remove timing pin (9) from storage hole (10) and install it in timing hole (11) in the fuel injection pump. Move the governor control lever until the timing pin goes through the notch in the rack. Push the timing pin into the fuel injection pump housing. If the timing pin goes into the timing groove (slot) in the fuel pump camshaft, the flange of the timing pin will be against the fuel injection housing.9. If the timing pin does not go into the fuel injection pump camshaft, see CHECKING MOVEMENT OF THE VARIABLE TIMING UNIT and ADJUSTING VARIABLE TIMING UNIT DRIVE GEAR in TESTING AND ADJUSTING.10. Remove the timing pin from the flywheel before the flywheel is removed.
TYPICAL EXAMPLE11. Loosen nut (12).
TYPICAL EXAMPLE12. Use tooling (B) to remove yoke (13) from the gear assembly.13. Remove the nut and yoke. Step 14 is for earlier engines only.
EARLIER ENGINE ONLY14. Remove tube assemblies (14), (15), (16) and (17). Steps 15 and 16 are for later engines only.
LATER ENGINE ONLY15. Loosen bolts (18) that hold the clamps for tube assembly (20) in place. Disconnect tube assembly (20) from the fitting in the flywheel housing.16. Remove bolts (19) that hold the clamps for tube assembly (21) in place. Remove tube assembly (21). Step 17 is for earlier engines only. 17. Disconnect tube assemblies (23) and (24). Remove bracket (22).
LATER ENGINE SHOWN18. Remove adapter (25) from the flywheel housing. 19. Remove O-ring seal (28) from adapter (25).20. Remove bearing (26) and lip type seal (27) from adapter (25). 21. Remove O-ring seal (29) from the flywheel housing. Remove washer (30) from the gear.
LATER ENGINE SHOWN22. Remove bolts (31) that hold the flywheel housing to plate (32) on the right side of the engine.
LATER ENGINE SHOWN23. Remove baffle (33) from the flywheel housing.24. Remove cover (34) from the flywheel housing. Remove the O-ring seals from the cover.25. Install tooling (B) and fasten a hoist to the flywheel housing as shown. Step 26 is for later engines only.
LATER ENGINE ONLY26. Turn fitting (38) on the top of the flywheel housing as shown.
Make sure shaft (35) does not come out with the flywheel housing. The shaft holds a gear in place.
LATER ENGINE SHOWN27. Install two 1/2"-13 NC guide pins (37). Remove the remainder of the bolts that hold the flywheel housing in place. Remove flywheel housing (36). The weight is 350 lb. (158 kg). 28. Remove washer (39) from the flywheel housing.Install Flywheel Housing
1. Make sure all parts are clean. Inspect all parts for damage and make replacements if needed. Put clean oil on all O-ring seals. 2. Install washer (1) on the flywheel housing as shown.
LATER MACHINE SHOWN3. Install tooling (A) and fasten a hoist. Install two 1/2"-13 NC guide pins (4). Make sure gasket (2) is in position. After assembly, cut (trim) the gasket even with the surfaces. Put flywheel housing (3) in position and install the bolts and nuts that hold the flywheel housing to the timing gear plate. 4. Install baffle (5). 5. Install O-ring seals (6) on the cover. Install the gasket and cover (7) on the flywheel housing. 6. Install O-ring seal (8) and washer (9). The adapter for the earlier engines does not have the "V" mark on it. 7. Use tooling (C) and a press and install bearing (10) with the bearing junction (joint) in alignment within 3° of the "V" mark on the adapter for later engines. Install the bearing with the bearing junction (joint) in position (X) for earlier engines. Install the bearing to a depth of .13 in. (3.29 mm) below the surface. The inside diameter of the bearing after assembly must be 2.5010 .0015 in. (63.525 0.038 mm).