8M2000491 Mercruiser PLUG

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     1P-2320     Combination Puller     1    
C
    1P-2321     Combination Puller     1    
9S-9153 Puller Jaws     3    Start By:
Remove the timing gear cover. Refer to Disassembly and Assembly, "Housing (Front) - Remove".
Remove the rocker shaft assembly and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Remove".
Remove the oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".Note: The engine oil pan is facing in the up direction in order to retain the lifters in position for this procedure.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Note: Ensure that the marks on the timing gears are in alignment. Align the fuel injection drive gear with the "33" mark with the "3" mark on the idler gear. Make an alignment of the "2" mark on the camshaft gear with the "22" mark on the idler gear. Align the "1" mark on the crankshaft gear with the "11" mark on the idler gear. The No. 1 cylinder is at the top center position when these marks are in alignment.
Rotate the engine at 180 degrees.
Illustration 1 g00532179
Use Tool (A) to remove bearing (1) from the front of camshaft gear (2) .Note: This step is necessary only if the camshaft gear is equipped with a bearing.
Illustration 2 g00532382
Do not damage the lobes or the bearings when the camshaft is removed or installed.
Position camshaft gear (2) so that the gear's slots align from the top to the bottom. Remove two bolts (3) and the washers that hold thrust plate (4). Carefully remove the camshaft, the thrust plate and the camshaft gear as an assembly.
Remove the 12 valve lifters. Refer to Disassembly and Assembly, "Lifter Group - Remove and Install".
Illustration 3 g00532384
Use tool (C) to remove camshaft gear (2) from camshaft (5). Remove thrust plate (4) .Installation Procedure 1
Note: In this installation procedure, the engine needs to remain in the upside-down position in order to keep the lifters in position while the camshaft is installed.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: During installation, ensure that camshaft (4) is clean and lubricate all of the components with clean engine oil.
Illustration 4 g00532385
Install thrust plate (4) onto camshaft (5) .
Always wear protective gloves when handling parts that have been heated.
Heat camshaft gear (2) in an oven to a maximum temperature of 150 °C (302 °F) and install camshaft gear (2) onto camshaft (5) .
Install the 12 valve lifters. Refer to Disassembly and Assembly, "Lifter Group - Remove and Install".Note: During installation, ensure that the marks on the timing gears are in alignment. Align the fuel injection drive gear with the "33" mark with the "3" mark on the idler gear. Make an alignment of the "2" mark on the camshaft gear with the "22" mark on the idler gear. Align the "1" mark on the crankshaft gear with the "11" mark on the idler gear. The No. 1 cylinder is at the top center position when these marks are in alignment.
Carefully install the camshaft assembly into the original location in the cylinder block.Note: Caution must be used when the camshaft is installed in order to not damage the camshaft l