803860T Mercruiser CYLINDER HEAD ASSEMBLY, Cylinder

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1U-8221 Lifting Sling 2
B 8T-5096 Dial Indicator Group 1
C - Straight Edge 1
D 194-3542 5 mm Allen Socket 1
E 165-2601 Silicon Sealant 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
If the crankshaft has been reground or if the crankshaft has been replaced, the height of the piston above the cylinder block must be inspected. It is necessary to remove the cylinder head in order to inspect the height of the piston above the cylinder block.
If the crankshaft has been reground or if the crankshaft has been replaced, ensure that the engine oil system is free from debris and contaminants.
Clean the crankshaft and inspect the crankshaft for wear or damage. Refer to Specifications, "Crankshaft" for more information. If necessary, replace the crankshaft or recondition the crankshaft.
If necessary, install the crankshaft gear. Refer to Disassembly and Assembly, "Crankshaft Gear - Remove and Install".
If necessary, install a new crankshaft timing ring. Refer to Disassembly and Assembly, "Crankshaft Timing Ring - Remove and Install". Note: The engine should be mounted on a suitable stand and placed in the inverted position.
Ensure that the parent bores for the crankshaft bearings in the cylinder block are clean. Ensure that the threads for the bearing bolts in the cylinder block are clean and free from damage.
Clean the crankshaft bearings and the thrust washers. Inspect the bearings and the thrust washers for wear or damage. If necessary, replace the bearings and the thrust washers. Note: If the crankshaft bearings are replaced, check whether oversize bearings were previously installed. If the thrust washers are replaced, check whether oversize thrust washers were previously installed.
Illustration 1 g01253240
Typical example
Illustration 2 g01889993
No. 1 Upper Main Bearing
Install upper bearings (9) to the cylinder block. Ensure that the locating tabs for the upper bearings are seated in the slots in the cylinder block. Note: Number 1 upper main bearing has an oil slot. See Illustration 2. All other upper bearings have a groove and two oil holes.
Lubricate upper bearings (9) with clean engine oil.
Illustration 3 g01254099
Typical example
Attach Tooling (A) and a suitable lifting device to crankshaft (8). Carefully lift the crankshaft into the cylinder block. The weight of the crankshaft is approximately 30 kg (66 lb). Remove Tooling (A). Note: Do not damage any of the finished surfaces on the crankshaft. Do not damage the bearing.
Illustration 4 g01254100
Typical example
For number three bearing, ensure that thrust washers (10) are clean and free from wear or damage. If necessary, replace the thrust washers. Lubricate thrust washers (10) with clean engine oil. Slide the thrust washers into position between the crankshaft and the cylinder block. Note: The grooves in the thrust washers must be located against the crankshaft.
Illustration 5 g01253146
Illustration 6 g01253137
Install lower bearings (5) into bearing caps (4). Ensure that the locating tabs for the lower bearings are correctly seated into the slots in the bearing caps. For number three bearing cap, ensure that thrust washers (7) are clean and free from wear or damage. If necessary, replace both the thrust washers. Lubricate thrust washers (7) with clean engine oil. Place the thrust washers into position on the bearing cap. Ensure that the locating tab is correctly seated in the bearing cap. Note: The lower bearing is a plain bearing that has no oil holes.
Lubricate lower bearings (5) and lubricate the journals of crankshaft (8) with clean engine oil. Install bearing caps (4) to the cylinder block. Note: Ensure the correct location and orientation of the bearing caps. The locating tabs for the upper and the lower bearings should be on the same side of the engine.