11977 Mercruiser GASKET SET, INTAKE MANIFOLD

A 01.40 Fuel delivery pump
- 3 -General:
- When installing the fuel delivery pump, make sure that the delivery and suction lines are connected correctly.Dismantling:
- Disconnect fuel feed line with clamp - 3 -- Separate the fuel lines from the delivery pump.- Unscrew and remove nuts with spring washers, and take off fuel delivery pump with O-ring.- Dismantle fuel delivery pump 1 in the numerical order of parts illustrated (Fig. 182). Since September 1992 fuel strainer 12 has been replaced by O-ring 5. Because of this, an input-side fuel filter must always be used.This input-side filter is supplied as a spare part with the fuel delivery pump and also with the repair kit for the fuel delivery pump.Assembling:
- Assemble by following the instructions in the reverse order as appropriate.
182A 03.00 Exhaust system
A 03.12 Removing and installing the silencer (muffler) enclosure(L 30, L 31, L 40, C/K)
Preparatory work:
- Remove the hood from the enclosure and air outlet duct; see M 35.00.Detaching:
- Take out hex bolts (184/1) and detach the connecting stub pipe with exhaust pipe (184/2). On more recent versions, the exhaust pipe is secured with a clip.- Take out the machine screws (184/3) and remove the connecting cover (184/4).- Unscrew and remove the hex bolts (185/1).- Remove the machine screws (186/1) and bolts (186/2).
184 (L3/228)
185 (L3/229)
186 (L3/230)- Lift off the capsule with exhaust silencer (muffler); see Fig. 187. In some cases a spacing plate is installed between the silencer enclosure and the air duct housing.- On the 2 - 3 L 40 from date of manufacture 5.85 on, 4 L 40 from 1.86 on and L 31, the connecting stub pipe (189/1), sealing washer (189/2) and plate (189/3) are deleted. Five sealing washers are installed between the silencer and the exhaust manifold.- Pull the upper and lower sections of the enclosure apart and lift out the silencer; see Fig. 188.Check the parts:
- Examine the enclosure sections and the silencer for fractured welds or tapped holes which are unfit for further use.Installing:
- Install by following the removal instructions in the reverse order as appropriate. The silencer must be installed without trapped stresses (a two-piece holder for the silencer has been installed since March 1989). Before installing the connecting stub pipe (189/1), check free movement of the sealing washer (189/2).Place the sealing washer in the connecting stub pipe and install the plate (189/3). It should be possible to move the sealing washer radially. Next, place the sealing washer on the silencer. Radial play must not exceed 0.1 mm. If necessary, renew the sealing washer.
187 (L3/231)
188 (L3/232)
189 (L3/233)A 04.00 Mechanical starting
A 04.10 Crank handle
Version A 04.10.1
Standard crank handle:This handle can be replaced at any time by one with kick-back damping if this becomes necessary or is required by regulations.
There is a risk of injury if the shaft of the crank handle or its tubular handgrip are worn.
Preparatory work: -; Dismantling: -; Checking / repairs:
- Visual inspection.- Inspect shaft 1 and tubular handgrip 2 for wear or breakage. If the shaft of the crank handle is worn, always renew the complete handle.The tubular handgrip can be renewed separately if necessary.
191Version A 04.10.2
Handle with kick-back damping:The version for M .. engines is marked A on its housing, and takes the place of the standard crank handle if required.
There is a risk of injury if the shaft of the crank handle or its tubular handgrip are worn.
Preparatory work: -; Dismantling:
- Remove parts in the order 1 ... 3 as illustrated.- Remove machine screws 4.- Take off cover 5 with great care, so that leaf spring 11 cannot escape. Risk of injury!- Remove parts in the order 6 ... 10 as illustrated.- Hold torsion spring 13 in position in order to maintain its tension.- Pull leaf spring 11 away from its locking pin and out of the hook eye on torsion spring 13.- Relieve torsion spring tension with a screwdriver blade. Caution - risk of injury!- Take off parts 12 and 13. Housing 14 remains in position with the other parts.
192Checking / repairs:
- Visual inspection:- Renew the complete starting handle if there is any damage in the area of cover 5 and/or housing 14.- If necessary, renew pivot bushings 15 and shaft sealing ring 16.- Examine tubular handgrip 7 for wear and/or other damage, particularly in the splined area.- Install end plug 8, avoiding damage to the splines. The end plug must be installed to prevent dirt and water from entering.- Check condition of bushing and leaf spring at lever 9.- Check condition of leaf spring 11 and torsion spring 13. Renew in case of doubt.- Check shaft 3 for wear and/or other forms of damage.- Renew O-rings and small parts.Assembling:
- Install parts 13 and 12. Use thread sealant D.- Make sure that the torsion spring is not trapped; insert its longer end into the groove on the corresponding locating pin.- Preload torsion spring 13 against the normal spring pressure until the hook eye of the spring engages behind the eye of the through-hole. Caution - risk of injury!- Hold torsion spring 13 in position to prevent spring pressure from being lost.- Push leaf spring 11 into the hook eye on torsion spring 13 and place on locking pin. The rolled end of the leaf spring must face toward the center of the housing.- Attach lever 9.- Push on tubular handgrip 7/8. Check splines, lever and leaf springs for free movement.- Apply app. 50 grams of lubricant K to the inside of housing 14 and over all mechanical parts.- Place a new gasket 6 on the housing.- Carefully place cover 6 over tubular handle 7.- Insert machine screws 4 and tighten them evenly in a crosswise pattern.- Install shaft 3 in the order 3 ... 1 as illustrated.- Check operation of the complete crank handle.A 04.20 Automatic decompressor (M 31, M 40, M 41)
The automatic decompressor has the following positions; Fig. 93: 0 = Operating position, with engine running1 = Permanent decompression, automatic device switched off2 = Automatic decompressor switched on, engine compression is built