863160 1 Mercruiser SERVICE MANUAL, #28

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 9U-6198 Crankshaft Turning Tool 1
A(2) 9U-7336 Housing 1
5P-7305 Engine Turning Tool 1
B 230-6283 Timing Pin (Crankshaft) 1
C 1P-2320 Combination Puller 1
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
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.Dispose of all fluids according to local regulations and mandates.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Put identification marks on all hoses, on all hose assemblies and on all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.
Do not disconnect the air lines until the air pressure in the system is at zero. If hose is disconnected under pressure it can cause personal injury.
Release the pressure from the air system.
Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct draining procedure.
Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install".
If the engine is equipped with a hydraulic pump on the rear of the air compressor, remove the hydraulic pump.
Use Tooling (A) in order to rotate the crankshaft so that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Finding Top Centre Position for No.1 Piston". Note: The air compressor must be timed with the engine in order to minimize engine vibration.
Illustration 1 g01272266
Typical example
Install Tooling (B) through Hole (X) in the front housing. Use Tooling (B) in order to lock the crankshaft.
Illustration 2 g01250794
Typical example
Disconnect coolant hose (1) and coolant hose (2) from air compressor (4).
Disconnect the air line from port (3) and air line from port (5).
Remove tube assembly (7) from air compressor (4) and from the cylinder block.
Remove bolts (8) and bolts (10) from support bracket (9) and remove the support bracket.
Illustration 3 g01250816
Typical example
Illustration 4 g01250889
Typical example
Support air compressor (4). Remove nuts (13) and remove the air compressor from the front housing.
If necessary, remove studs (12) from the front housing.
Remove O-ring seal (18) from air compressor (4).
If necessary, remove bolts (15) and remove plate (14). Remove O-ring seal (11) from plate (14). Refer to Illustration 3.
If necessary, remove nut (17) and remove the spring washer. Use Tooling (C) in order to remove gear (16) from the crankshaft of the air compressor. Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
B 230-6283 Timing Pin (Crankshaft) 1
D 4C-9506 Retaining Compound 1
E 1U-6396 O-Ring Assembly Compound