816550 Mercruiser INJECTION PUMP

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     6V-9120     Socket (1)     1    
B     8T-5096     Dial Indicator     1    
( 1 ) Tool (A) is a 46 mm socket.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g00604687
If the thrust washers were removed, then install a thrust washer (11) on the rear face of the crankshaft with the oil groove toward the outside.
Place the upper halves of crankshaft main bearings (10) in the cylinder block. Place the lower halves of the crankshaft main bearings in crankshaft main bearing caps. Install the bearings with the main bearing tabs in the correct position. Lubricate the bearings with clean engine oil.
Illustration 2 g00604584
Lubricate the crankshaft journals with clean engine oil. Fasten a suitable lifting device and straps to crankshaft (9). The weight of the crankshaft for the 3064 engine is 84 kg (185 lb). The weight of the crankshaft for the 3066 engine is 99 kg (220 lb). Position crankshaft (9) onto the upper halves of the crankshaft main bearings.Note: Be careful not to damage the finished surfaces on the crankshaft.
Illustration 3 g00604582
Install main bearings into main bearing caps (8). Install the bearings with the main bearing tabs in the correct position. Lubricate the bearings with clean engine oil.
Place the thrust washers on the rear main bearing cap. Install the rear main bearing cap and two seals on the rear journal of the cylinder block.
Install crankshaft main bearing caps (8). Put clean engine oil on the threads of the main bearing cap bolts. Install main bearing cap bolts (7). Tighten the bolts evenly to a torque of 137 5 N m (101 4 lb ft).Note: Ensure that the crankshaft main bearing caps are installed in the original locations.
Cut off the excess length on the two seals on the rear journal of the cylinder block.
Illustration 4 g00604753
Check the end play of the crankshaft with Tool (B). The end play must be 0.100 to 0.264 mm (0.0039 to 0.0104 inch). Refer to the Testing and Adjusting Module, "Basic Block" for more information on crankshaft end play.
Illustration 5 g00604552
Apply a light coat of clean engine oil to the connecting rod bearing surfaces and to the connecting rod journals. Install the connecting rods onto the connecting rod journals.
Install the lower half of the connecting bearings into the corresponding connecting rod caps and install connecting rod caps (6) .Note: Align the tabs on the back of the connecting rod bearings with the tab grooves in the connecting rod caps.Install the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Install".
Illustration 6 g00604549
Check for free crankshaft rotation by rotating the crankshaft for two complete revolutions. Use Tool (A) on crankshaft pulley nut (4) in order to rotate the crankshaft.
Illustration 7 g00604637
Install O-ring seal (3) on oil supply tube (2) .
Illustration 8 g00604627
Position oil supply tube (2). Install two bolts (1) in order to secure the oil supply tube to the cylinder block.End By:
Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".
Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Remove and Install".
Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install".
Install the crankshaft rear seal, if the crankshaft wear sleeve was removed. Refer to Disassembly and Assembly, "Crankshaft Rear Seal - Install".