5J31200TP Mercruiser STERNDRIVE, Bravo-I (1.50:1 Ratio)

Start By:a. remove exhaust manifoldb. remove water temperature regulatorc. remove rocker arm and shaft assembliesd. remove electronic unit injectorse. remove valve cover basef. remove fan drive 1. Remove cover (1) from timing gear cover (2). 2. Disconnect the wire and remove timing sensor (5).3. Remove one bolt (3), and install a guide bolt [Tool (A)], as shown. Remove the remaining six bolts (3).4. Use Tool (B) and a strap to attach a hoist to gear (4). Remove gear (4). 5. Remove bolts (6), thrust washer (7) and adapter (8). Remove Tool (B). 6. Disconnect fuel line (9) from the back of cylinder head (10). 7. Disconnect lines (11) and (12) from the air compressor.8. Remove the bolt and clamp (13) from fuel line (14). Remove fuel line (14). 9. Remove the bolt and wiring harness support clip (16).10. Disconnect the wires from sensors (15), (17) and ground (18). 11. Remove the bolts and spacers (20) and (21) from bracket (19). 12. Remove head bolts (22). 13. Install Tool (B)14. Support the cylinder head (10) with a hoist, as shown. Remove cylinder head (10). Cylinder head (10) weighs 148 kg (325 lb). 15. Remove cylinder head gasket (23). 16. Remove O-ring seals (24) and seals (25).17. Remove O-ring seal (26). If the cylinder head was removed from the cylinder block because of head gasket failure, refer to Special Instruction, SEHS9564 for additional information. The following steps are for installing the cylinder head.
Thoroughly clean the spacer plate and bottom surface of the cylinder head assembly. A new spacer plate gasket must be installed when the cylinder head assembly is removed. Refer to the Disassembly and Assembly, "Spacer Plate" for additional information.
Put a thin film of clean engine oil on the seal and O-ring seals at installation.18. Replace seals (24), (25), and (26). Install a new gasket (23). 19. Fasten a hoist to cylinder head assembly (10). Position cylinder head assembly (10) onto the spacer plate. The bolts marked "X" are 216 mm (8.5 inch) in length. The remainder of the bolts are 194 mm (7.6 inch) long.20. Put 6V-4876 Molykote Paste Lubricant on the washers, threads, and the underside of bolt heads (22). Install cylinder head bolts (22) and washers. Tighten bolts (22) as follows:a. Tighten bolts (22) in the numbered sequence to a torque of 270 15 N m (200 11 lb ft).b. Tighten bolts (22) in the numbered sequence to a torque of 450 20 N m (333 15 lb ft).c. Again, tighten bolts (22) in the numbered sequence to a torque of 450 20 N m (333 15 lb ft).21. Reverse the procedures and Steps 4 through 11. Ensure that all surfaces are clean. Check the condition of all components, O-ring seals and gaskets. Use new parts for replacement if needed. Lubricate the O-ring seals with clean engine oil when assembling. Refer to the System Operation/Testing and Adjusting for additional information.
After the cylinder head assembly has been removed, and the camshaft gear is installed, it is necessary to check for correct adjustment of backlash between the camshaft and idler gears. Improper adjustment can result damaged components. Refer to the Systems Operation/Testing and Adjusting, "Setting Backlash For Camshaft And Adjustable Idler Gear" for the correct tooling and procedure.
22. Install camshaft gear (4). Measure for backlash between gear (4) and idler gear. Refer to the Testing and Adjusting and adjust, as needed.23. Reverse the procedures and Steps 1 through 3.End By:a. install fan driveb. install valve cover basec. install electronic unit injectorsd. install rocker arm and shaft assembliese. install water temperature regulatorf. install exhaust manifold