808231 Mercruiser INJECTOR TUBE (#7 CYLINDER)

(1) Make expansion of tube assembly to make a tight fit, then flare end of tube.(2) Thickness of top plate ... .486 .001 in.(12.34 0.03 mm) Thickness of gasket between top plate and cylinder block ... .008 .001 in.(0.20 0.03 mm)Height of liner over plate under installation pressure ... .005 .003 in.(0.13 0.08 mm)Maximum permissible difference in height of liners next to each other in the same spacer plate ... .002 in.(0.05 mm)Maximum permissible difference between high and low measurements made at four places around each cylinder liner ... .002 in.(0.05 mm)(3) Length of dowels (four) out of the block face ... .88 in.(22.4 mm)(4) Bore in bearings for camshaft ... 2.6243 .0012 in.(66.657 0.030 mm)(5) Bore in block for main bearing ... 4.6245 .0005 in.(117.462 0.013 mm) Alignment for the bore in the block for the main bearings ... .000 to .003 in.(0.00 to 0.08 mm)(6) Clearance between main bearing caps and cylinder block ... .0000 to .0005 in.(0.000 to 0.013 mm) Maximum permissible clearance between cap for main bearings and cylinder block ... .0012 in.(0.030 mm)Install caps with part number toward front.(7) Make expansion of tube assembly to make a tight fit, then flare end of tube.(8) Bore in block for bearings for camshaft ... 2.874 to 2.875 in.(72.99 to 73.03 mm)(9) Torque for studs for main bearing caps ... 170 20 lb. ft.(230 25 N m)(10) Torque for nuts holding caps for main bearings: a. Put crankcase oil on threads and washer face.b. Tighten both nuts to ... 100 5 lb. ft.(135 7 N m)c. Put a mark on each nut and cap.d. Tighten each nut from mark ... 120°(11) Dimension from center of main bearing bore to top of cylinder block (new) ... 23.6945 .0035 in.(601.840 0.089 mm)(12) Dimension from center of main bearing bore to bottom of cylinder block (new) ... 3.750 .001 in.(95.28 0.03 mm)(Engines Without Spacer Plate)
(1) Torque for 7/8 in. studs for head ... 170 20 lb. ft.(230 25 N m)(2) Torque for 5/8 in. studs for head ... 75 10 lb. ft.(100 14 N m)(3) Depth of bore in block for liner ... .492 to .494 in.(12.50 to 12.55 mm) Maximum permissible depth of bore after reconditioning ... .538 in.(13.67 mm)Height of liner over block, under installation pressure ... .004 to .008 in.(0.10 to 0.20 mm)Maximum permissible difference in height of liners next to each other under the same cylinder head ... .002 in.(0.05 mm)Maximum permissible difference between high and low measurements made at four places around each cylinder liner ... .002 in.(0.05 mm)(4) Make expansion of tube assembly to make a tight fit, then flare end of tube.(5) Bore in bearings for camshaft ... 2.6243 .0012 in.(66.657 0.030 mm)(6) Bore in block for main bearing ... 4.6245 .0005 in.(117.462 0.013 mm) Alignment for the bore in block for the main bearings ... .000 to .003 in.(0.00 to 0.08 mm)(7) Clearance between main bearing caps and cylinder block ... .0000 to .0005 in.(0.000 to 0.013 mm) Maximum permissible clearance between cap for main bearings and cylinder block ... .0012 in.(0.030 mm)Install caps with part number toward front.(8) Make expansion of tube assembly to make a tight fit, then flare end of tube.(9) Bore in block for bearings for camshaft ... 2.874 to 2.875 in.(72.99 to 73.03 mm)(10) Torque for studs for main bearing ... 170 20 lb. ft.(230 25 N m)(11) Torque for nuts holding caps for main bearings: a. Put crankcase oil on threads and washer face.b. Tighten both nuts to ... 100 5 lb. ft.(135 7 N m)c. Put a mark on each nut and cap.d. Tighten each nut from mark ... 120°(12) Dimension from center of main bearing bore to top of cylinder block (new) ... 24.1875 .0035 in.(614.363 0.089 mm)(13) Dimension from center of main bearing bore to bottom of cylinder block (new) ... 3.750 .001 in.(95.28 0.03 mm)