5111200LP Mercruiser STERN DRIVE, (1.47:1 RATIO)

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Guide Bolt
(M16 by 115mm) 2
B 8T-3052 Degree Wheel 1
C 1U-6396 O-Ring Assembly Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Thoroughly clean the mating surfaces of the cylinder head and the cylinder block. Do not damage the mating surfaces of the cylinder head of the cylinder block. Ensure that no debris enters the cylinder bores, the coolant passages, or the lubricant passages.
Inspect the mating surface of the cylinder head for distortion. Refer to Specifications, "Cylinder Head" for more information. If the mating surface of the cylinder head is distorted beyond maximum permitted limits, replace the cylinder head.
If necessary, install the inlet manifold to the cylinder head. Refer to Disassembly and Assembly, "Inlet manifold - Remove and Install".
Illustration 1 g01340176
Inspect dowels (18) for damage. If necessary, replace the dowels in the cylinder block.
Install Tooling (A) to the cylinder block.
Align cylinder head gasket (17) with dowels (18). Install cylinder head gasket (17) onto the cylinder block.
Illustration 2 g01340086
Typical example
Use a suitable lifting device (16) to lift cylinder head (15). The weight of the cylinder head is approximately 66 kg (145.5 lb). Note: A spreader bar must be used in order to distribute the weight of the cylinder head during the lifting operation.
Use Tooling (A) to align the cylinder head with the cylinder block. Install the cylinder head to the cylinder block. Note: Ensure that the cylinder head is correctly positioned on dowels (18).
Remove Tooling (A).
Illustration 3 g01340188
Clean bolts (14). Follow Steps 10.a for the procedure to inspect the bolts.
Use a straight edge to check the threads of the bolts. Refer to Illustration 3. Replace any bolts that show visual reduction in the diameter of the thread over length (Y).
Lubricate the threads and the shoulder of bolts (14) with clean engine oil.
Illustration 4 g01340081
Illustration 5 g01340192
Install bolts (14) to cylinder head (16).
Tighten the bolts to a torque of 50 N m (37 lb ft) in the numerical sequence. Refer to Illustration 5.
Tighten the bolts to a torque of 100 N m (74 lb ft) in the numerical sequence. Refer to Illustration 5.
Turn the bolts through an additional 225 degrees in the numerical sequence. Refer to Illustration 5. Use Tooling (B) to achieve the correct final torque.
Illustration 6 g01340080
Typical example
Use Tooling (C) in order to lubricate the O-ring seals. Install new O-ring seals (12) and (13) to bypass tube (11). Install the bypass tube in the cylinder head. Install bolts (10). Tighten the bolts to a torque of 22 N m (16 lb ft).
Illustration 7 g01340077
Typical example
Remove the plugs and caps from the ports and tube assemblies.
Install tube assembly (8) for the fuel return to the cylinder head and to the transfer pump. Secure the tube clips for tube assembly (8).
If the engine has a wastegate solenoid, install tube assembly (9) for the wastegate solenoid to the cylinder head. Secure the tube clips for tube assembly (9).
Illustration 8 g01340075
Typical example
Follow Steps 20.a and 20.b in order to connect harness assembly (4) to inlet air temperature sensor (7).
Connect harness assembly (4) to inlet air temperature sensor (7).
Slide the locking tab into the locked position.
Follow Steps 21.a and 21.b in order to connect harness assembly (4) to boost pressure sensor (6).
Connect harness assembly (4) to boost pressure sensor (6).
Slide the locking tab into the locked position.
Follow Steps 22.a and 22.b in order to connect harness assembly (4) to coolant temperature sensor (5).
Connect harness assembly (4) to coolant temperature sensor (5).
Slide the locking tab into the locked position.
Use new cable straps in order to secure the harness assembly to the cylinder head and to the inlet manifold. Ensure that the harne