8866A38 Mercruiser GEAR HOUSING ASSEMBLY

Table 1
Required Tools
Tool Part Number Part Description Qty
A 9U-6195 Valve Spring Compressor 1 Start By:
Remove the cylinder head assembly. Refer to Disassembly and Assembly, "Cylinder Head - Remove". Note: Ensure that the machined face of the cylinder head is kept on a clean, soft surface in order to prevent damage to the machined surface.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01015306
Typical example
Clean the bottom face of the cylinder head. Use a dial indicator to check the depth of the valves below the face of the cylinder head before the valve springs are removed. Refer to the illustration 1 and refer toSpecifications, "Cylinder Head Valves" for the correct dimensions.
Place an index mark on the heads of the inlet valves and the exhaust valves for installation purposes.
Illustration 2 g00936484
Illustration 3 g00953724
Ensure that the valve spring is compressed squarely or damage to the valve stem may occur.
Use the Tooling (A) to compress spring (3).
Remove the valve keeper (1).
The valve spring keepers can be thrown from the valve when the valve spring compressor is released. Ensure that the valve spring keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve spring keepers and valve springs during the installation of the valves.
Carefully release the pressure on the Tooling (A) and remove the Tooling (A).
Remove the valve spring retainer (2).
Remove the valve spring (3).
Remove the valve stem seal (4) for the inlet valve or the exhaust valve.
Remove the inlet valve (5) or the exhaust valve (6).
Repeat Step 3 to Step 9 for each inlet valve (7) and for each exhaust valve (8). Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A 9U-6195 Valve Spring Compressor 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 4 g00953724
Carefully clean the bottom face of the cylinder head. Ensure that there is no debris in the inlet and exhaust ports. Also ensure that there is no debris in the coolant passages and in lubrication passages. Inspect the cylinder head. Refer to the Testing and Adjusting Manual, "Cylinder Head Inspect" for further information.
Inspect all of the valve seats for wear and for damage. Refer to the Specifications Manual, "Cylinder Head Valves" for further information. Also refer to this Disassembly and Assembly Manual, "Inlet and Exhaust Valve Seat Inserts - Remove and Install" and refer to Testing and Adjusting Manual, "Valve Depth - Inspect " for further information. Replace any worn parts.
Inspect all of the valve guides for wear and for damage. Refer to the Specifications Manual, "Cylinder Head Valves" for further information. Also refer to this Disassembly and Assembly Manual, "Inlet and Exhaust Valve Guides - Remove and Install" and refer to Testing and Adjusting Manual, "Valve Guide - Inspect" for further information. Replace any worn parts.
Inspect the valves if the valves are not replacement parts. Refer to the Specifications Manual, "Cylinder Head Valves" for further information.
Lubricate the stem of the inlet valve (5) and the stem of the exhaust valve (6) with clean engine oil.
Install inlet valve (5) and exhaust valve (6) in the respective positions.
Carefully turn over the cylinder head and ensure that all of the valves remain in place. Place the machined surface of the cylinder head onto a clean, soft surface. Note: The valve guide must be clean and dry before installing the valve stem seal.
Install a new valve stem seal (4) for the inlet valve or the exhaust valve on the valve guide.
Inspect the valve springs (3) for wear and for the correct installed length. Refer to the Specifications Manual, "Cylinder Head Valves " for further information on the correct installed length of the valve springs (5). Replace any worn parts.
Install the valve spring (3).
Install the valve spring retainer (2).
Illustration 5