811585 Mercruiser GUIDE

Illustration 1 g00295804 (1) Fuel injection pump gear Bore ... 36.00 to 36.06 mm (1.417 to 1.420 inch)Tighten the four bolts to the following torque. ... 28 N m (21 lb ft)Tighten the two torx screws to the following torque. ... 9 N m (7 lb ft)Note: The torx screws retain the timing plate on the front of the gear. This plate is installed in the factory after the fuel injection pump timing has been accurately set to the top center position on the compression stroke of the No. 1 cylinder. If the timing plate is moved, the timing of the fuel injection pump must be set.Note: The crankshaft must not be turned unless the fuel injection pump gear is installed.Note: Do not remove the nut that retains the hub of the fuel injection pump to the shaft of the fuel injection pump. If the hub is removed, the hub must be positioned by correctly trained personnel and special test equipment. (2) Camshaft gear Diameter of the camshaft gear bore ... 34.930 to 34.950 mm (1.3752 to 1.3760 inch)Outside diameter of camshaft hub ... 34.900 to 34.920 mm (1.3741 to 1.3747 inch)Clearance between the camshaft gear and the camshaft hub ... 0.008 to 0.048 mm (0.0003 to 0.0019 inch) (3) Tighten the bolt for the camshaft gear to the following torque. ... 95 N m (70.0682 lb ft) (4) Idler gear and hub Diameter of the idler gear bore ... 57.14 to 57.18 mm (2.250 to 2.251 inch)Width of the idler gear and split bearing assembly ... 30.14 to 30.16 mm (1.186 to 1.187 inch)Inside diameter of the idler gear bearing ... 50.78 to 50.80 mm (1.999 to 2.000 inch)Outside diameter of the idler gear hub ... 50.70 to 50.74 mm (1.996 to 1.998 inch)Clearance of the bearing on the idler gear hub ... 0.04 to 0.10 mm (0.002 to 0.004 inch)Idler gear end play ... 0.10 to 0.20 mm (0.004 to 0.008 inch)Maximum permissible end play ... 0.38 mm (0.015 inch)Backlash (minimum) ... 0.08 mm (0.003 inch) (5) Tighten the bolts for the idler gear to the following torque: ... 44 N m (33 lb ft) (6) Crankshaft gear Diameter of the bore of the crankshaft gear ... 47.625 to 47.650 mm (1.8750 to 1.8760 inch)Outside diameter of the crankshaft for the crankshaft gear ... 47.625 to 47.645 mm (1.8750 to 1.8758 inch)Clearance of the crankshaft gear on the crankshaft for a press fit ... 0.015 0.035 mm (0.0006 0.0014 inch) (7) Oil pump idler gear Inside diameter of the bearing ... 22.230 to 22.260 mm (0.8750 to 0.8766 inch)Outside diameter of the idler gear shaft ... 22.19 to 22.21 mm (0.873 to 0.874 inch)Clearance of the gear on the shaft ... 0.020 to 0.066 mm (0.0008 to 0.0026 inch)Idler gear end play ... 0.012 to 0.643 mm (0.0005 to 0.0253 inch)Timing gear backlash (minimum) ... 0.08 mm (0.003 inch)Balancer (If equipped)
Diameter of drive shaft for front bearing ... 28.562 to 28.575 mm (1.1245 to 1.1250 inch)Diameter of drive shaft for rear bearing ... 23.787 to 23.800 mm (0.9365 to 0.9370 inch)Number of teeth on gear of drive shaft ... 21Backlash from gear of drive shaft to idler gear ... 0.17 to 0.29 mm (0.0067 to 0.0114 inch)End play of drive shaft ... 0.13 to 0.30 mm (0.0051 to 0.0118 inch)Diameter of bore for front bearing of drive shaft ... 34.912 to 34.937 mm (1.3745 to 1.3755 inch)Diameter of bore for rear bearing of drive shaft ... 29.972 to 29.993 mm (1.1800 to 1.1808 inch)Diameter of bore for idler gear ... 47.64 to 47.65 mm (1.8756 to 1.8760 inch)Diameter of hub of idler gear ... 38.09 to 38.10 mm (1.4996 to 1.5000 inch)End play of idler gear ... 0.07 to 0.23 mm (0.0028 to 0.0091 inch)Thickness of thrust washer for idler gear ... 4.14 to 4.29 mm (0.1630 to 0.1689 inch)Number of teeth on idler gear ... 37Inside diameter of bushes in balancer frame and end cover ... 38.133 to 38.174 mm (1.5013 to 1.5029 inch)Diameter of spigots for balance weights ... 38.054 to 38.069 mm (1.4982 to 1.4988 inch)Fit of spigot in bush ... 0.064 to 0.120 mm (0.0025 to 0.0047 inch)End play of balance weights ... 0.19 to 0.40 mm (0.0075 to 0.0157 inch)Backlash of gears on balance weights ... 0.10 to 0.27 mm (0.0039 to 0.0106 inch)Backlash of drive gear to spline on balance weight ... 0.05 to 0.20 mm (0.0020 to 0.0079 inch)Number of teeth on drive gear ... 24Number of teeth on spline on balance weight ... 16