802929 Mercruiser FLANGE, Clamping

Illustration 1 g00525341
(1) Crankshaft main bearing journalMeasure the main bearing journal. The diameter of the crankshaft is given in Table 2.
Table 1
Main Bearing Journal    
Original size journal (1)    
77.955 to 77.970 mm (3.0691 to 3.0697 inch)    
Undersize journal
0.25 mm (0.010 inch)    
77.705 to 77.720 mm (3.0393 to 3.0598 inch)    
Undersize journal
0.50 mm (0.020 inch)    
77.455 to 77.470 mm (3.0494 to 3.0500 inch)    
Undersize journal
0.75 mm (0.030 inch)    
77.205 to 77.220 mm (3.0396 to 3.0402 inch)    
( 1 ) Regrind the main bearing journals to the next undersize dimension if the repair limit of 77.850 mm (3.0650 inch) is exceeded.
Illustration 2 g00554211
(2) Main bearing cap Ensure that the main bearings are correctly installed in the cylinder block and the main bearing caps. Put the main bearing caps in position in the cylinder block. Put clean engine oil on the main bearing bolts. Install the bolts and tighten the bolts to the following torque. ... 103 5 N m (76 4 lb ft) (3) Dial indicator Measure the main bearing bores with a dial indicator. Subtract the diameter of the crankshaft journal from the inside diameter of the main bearing in order to determine the bearing clearance on the main journal. Clearance between crankshaft journal and main bearing ... 0.050 to 0.110 mm (0.0020 to 0.0043 inch)Note: Replace the bearings or refinish the crankshaft to the next undersize bearing if the main bearing clearance exceeds 0.20 mm (0.008 inch). Refer to Table 2 for dimensions of undersize journals.Note: The allowable tolerance for main bearing journals that are out of round is 0.010 mm (0.0004 inch). The maximum repair limit is 0.030 mm (0.0012 inch). If the repair limit is exceeded, regrind the bearing journals to the specified dimension.Note: The maximum service limit for the crankshaft journal is 77.100 mm (3.0354 inch). Replace the crankshaft if the crankshaft journal is worn beyond this specification.
Illustration 3 g00554249
(4) Crankshaft Support the crankshaft in a set of blocks. Measure the runout dimension at the center journal. Maximum runout ... 0.10 mm (0.004 inch)Note: Replace the crankshaft if the runout exceeds the repair limit of 0.13 mm (0.0051 inch).
Illustration 4 g00525383
(5) The width of the crankshaft main bearing journal ... 31 0.039 mm (1.2205 0.0015 inch)
Illustration 5 g00827942
(6) Put main bearing (6) and the thrust plates in the block and install the crankshaft. Put engine oil on the bolt threads. Tighten the bolts to the following torque. ... 103 5 N m (76 4 lb ft) (7) Thrust plate
Illustration 6 g00827945
(8) Position the dial indicator and measure the crankshaft end play. End play ... 0.100 to 0.264 mm (0.0039 to 0.0104 inch)Note: The maximum repair limit is 0.300 mm (0.0118 inch).Replace the standard thrust plates if the end play exceeds the standard clearance. Three oversize thrust plates are available as replacements if the end play still exceeds the maximum limit. Generally, the rear journal is likely to be worn more rapidly than the front journal. Generally, the rear thrust plate will be replaced. Refer to Table 3 for oversize thrust plates.
Table 2
Dimensions for Grinding of Crankshaft
Oversize Thrust Plates    
Oversize Thrust Plate     Oversize (front or rear)     Oversize (front or rear)     Tolerance    
+0.15 mm (+0.006 inch)    
31.15 mm (1.226 inch)    
31.30 mm (1.232 inch)    
+0.039 mm (+0.0015 inch)    
+0.30 mm (+0.012 inch)    
31.30 mm (1.232 inch)    
31.45 mm (1.238 inch)    
+0.039 mm (+0.0015 inch)    
+0.45 mm (+0.018 inch)    
31.45 mm (1.238 inch)    
31.60 mm (1.244 inch)    
+0.039 mm (+0.0015 inch)