811440T Mercruiser EXHAUST MANIFOLD

1. Remove bell assembly (1). Remove bolts (3) and cover (2). 2. Loosen setscrew (4) and remove guide (5), the relief valve spring, and the plunger. 3. Remove inner rotor (6) and outer rotor (7). 4. Measure the inside diameter of bearing (8). The inside diameter must be 71.22 0.05 mm (2.804 .002 in). If a replacement of the bearing is needed, put a mark on the timing gear cover as to the location of the joint in the bearing and remove the bearing.Install Oil Pump & Relief Valve (With Plunger Bypass Valve)
1. Thoroughly clean all of the parts. Put oil on all of the parts before assembly. 2. If the bearing was removed from the timing gear cover, install a new bearing with tool (A). Make sure the joint in the bearing is installed in the position as shown. 3. Install inner rotor (6) and outer rotor (7).4. Measure the clearance between the rotors with a feeler gauge. The clearance must be 0.05 to 0.15 mm (.002 to .006 in). The maximum permissible clearance is 0.23 mm (.009 in). Make a replacement of BOTH rotors if the clearance is not correct. The rotors cannot be ordered separately. 5. Put the plunger and the spring in position and push guide (5) into cover (2) with a press until the lip on the guide is even with the finished surface on the cover. Make sure the flat surface on the guide is in alignment with setscrew (4). Tighten the setscrew. 6. Put cover (2) in position and install the locks and bolts (3).7. Check the oil pump end clearance with a feeler gauge. The end clearance must be 0.069 to 0.135 mm (.0027 to .0053 in). If the clearance is not correct, make a replacement of BOTH rotors or cover (2). The rotors cannot be ordered separately. 8. Put bell assembly (1) on cover (2) and install the bolts and locks to hold it.End By:a. install timing gear cover & oil pumpRemove Oil Pump & Relief Valve (With Belleville Washer Bypass Valve)
Start By:a. remove timing gear cover & oil pump 1. Bend the tabs of the locks and remove the bolts and bell assembly (1) from pump cover (2). 2. Bend the tabs of the locks and remove the bolts and cover (2). 3. Remove bolt (5), the washer, cover (4), and relief valve assembly (3). 4. Remove inner rotor (6) and outer rotor (7). 5. Measure the inside diameter of bearing (8). The inside diameter must be 71.22 0.05 mm (2.804 .002 in). If a replacement of the bearing is needed, put a mark on the timing gear cover as to the location of the joint in the bearing and remove the bearing.Install Oil Pump & Relief Valve (With Belleville Washer Bypass Valve)
1. Thoroughly clean all of the parts. Put oil on all of the parts before assembly. 2. If the bearing was removed from the timing gear cover, install a new bearing with tool (A). Make sure the joint in the bearing is installed in the position as shown. 3. Install inner rotor (6) and outer rotor (7).4. Measure the clearance between the rotors with a feeler gauge. The clearance must be 0.05 to 0.15 mm (.002 to .006 in). The maximum permissible clearance is 0.23 mm (.009 in). Make a replacement of BOTH rotors if the clearance is not correct. The rotors cannot be ordered separately. 5. Install valve assembly (3), cover (4), the washer, and bolt (5). 6. Put cover (2) in position and install the bolts and locks to hold it.7. Check the oil pump end clearance with a feeler gauge. The end clearance must be 0.069 to 0.135 mm (.0027 to .0053 in). If the clearance is not correct, make a replacement of BOTH rotors or cover (2). The rotors cannot be ordered separately. 8. Put bell assembly (1) in position and install the bolts and locks to hold it.End By:a. install timing gear cover & oil pump