861676T09 Mercruiser PUMP ASSEMBLY, Fuel

Illustration 1 g00465053
(1) ChamferThe chamfer faces the front of the engine. (2) Upper half of the main bearing with the oil groove (3) Upper half of main bearing cap (4) Notch on the upper half of the main bearingThe notch in this position on the bearing cap faces the rear of the engine. (5) Connecting rod journal Diameter of the connecting rod journal ... 51.964 to 51.975 mm (2.0458 to 2.0463 inch) Service limit ... 51.90 mm (2.043 inch)Note: If the service limit is exceeded, then the crankshaft must be replaced. (6) Main bearing journal Diameter of main bearing journal ... 67.957 to 67.970 mm (2.6755 to 2.6760 inch) Service limit ... 67.90 mm (2.673 inch)Note: If the service limit is exceeded, then the crankshaft must be replaced. (7) Thrust washers Standard thickness ... 2.95 to 3.00 mm (0.116 to 0.118 inch) Service limit ... 2.80 mm (0.110 inch) (8) Lower half of the main bearingThe lower half of the main bearing does not have an oil groove.Measure Wear on the Crankshaft
Illustration 2 g00464232
Measure the diameters of the crankshaft journals that are shown in Illustration 2. This procedure measures wear and eccentricity. Measure the diameters of the connecting rod journals (5) and main journals (6) in positions (1) and (2) . Measure the diameter (A) and (B) in each position. (1) (2) Taper The difference between positions (1) and (2) must not be more than the following value. ... 0.05 mm (0.002 inch) (A) (B) Eccentricity The eccentricity must be the following value or the eccentricity must be less than the following value. ... 0.03 mm (0.001 inch) Service limit ... 0.06 mm (0.002 inch)Measure the Main Bearing Clearance
Illustration 3 g00464228
Front main bearingMeasure the bore of the main bearings in positions (1) and (2) . Measure the bore in the directions (A) and (B) in each position.Refer to "Measure Wear on the Crankshaft". Subtract the smallest diameter of the crankshaft journal from the largest main bearing bore. The remainder is the clearance between the main bearing and the crankshaft journal.Clearance Standard clearance ... 0.044 to 0.102 mm (0.0017 to 0.0040 inch) Service limit ... 0.20 mm (0.008 inch)If the measurements are outside of the tolerances, the main bearings or the crankshaft must be replaced.The end play is measured on the front main bearing journal. End play of the crankshaft ... 0.10 to 0.40 mm (0.004 to 0.016 inch) Service limit ... 0.50 mm (0.020 inch)Crankshaft Main Bearing Cap
Illustration 4 g00463533
Refer to the Specifications Module, "Cylinder Block" topic for additional information about the front crankshaft bearing. (1) Tighten the crankshaft main bearing cap bolt to the following torque. ... 52 N m (38 lb ft) (2) Upper half of bearing capOne of the halves of the crankshaft bearing has an oil groove. The half of the bearing with the oil groove is installed in the upper half of the bearing cap. (3) Lower half of the bearing cap (4) DowelTwo dowels are installed in each bearing cap in order to correctly align the two halves of the bearing cap.
Illustration 5 g00846004
(5) Tighten the retaining bolts for the crankshaft to the following torque. ... 27 N m (20 lb ft) (6) Tighten the allen head screw to the following torque. ... 52 N m (38 lb ft)