15920A54 Mercury LANYARD ASSEMBLY - WITH STOP SWITCH

Do not grind or polish crankshaft bearing journals. Grinding or polishing removes the hardened surface of the journals, resulting in engine failure.
The bearing journal surface hardness is extremely thin, .0003 to .0005 in. (0.008 to 0.013 mm). It is important to maintain rigid size control on the bearing journals. Connecting rod journal diameter is 2.7500 .0004 in. (69.850 0.010 mm). Connecting rod journal minimum permissible diameter is 2.7486 (69.814 mm). Main bearing journal diameter is 3.5000 .0005 in. (88.900 0.013 mm). Main bearing journal minimum permissible diameter is 3.4985 (88.862 mm). Measure the journals around the diameter to find the maximum wear point. Replace the crankshaft if excessive wear is noted on any journal. To check crankshaft for straightness, support at each end in V-blocks, measure the total indicator reading at the center main journal. The maximum permissible runout is .006 in. (0.15 mm) for 4.1 stroke, .007 in. (0.18 mm) for 4.5 stroke, and .008 in. (0.20 mm) for 5.0 stroke crankshafts.With the crankshaft installed in the cylinder block, check crankshaft end play. End play with new bearings should be .006 .003 in. (0.15 0.08 mm). Maximum allowable end play is .014 in. (0.36 mm).Crankshaft
9L9230 Crankshaft, part of 9L7604 Crankshaft Assembly.9L9231 Crankshaft, part of 9L7603 Crankshaft Assembly.9L9232 Crankshaft, part of 9L7605 Crankshaft Assembly.9N8013 Crankshaft, part of 9L6266 Crankshaft Assembly.4N8453 Crankshaft, part of 4N9054 Crankshaft Assembly.4N8454 Crankshaft, part of 4N9055 Crankshaft Assembly.9N300 Crankshaft, part of 9N305 Crankshaft Assembly.9N303 Crankshaft, part of 9N304 Crankshaft Assembly.Reconditioning of these crankshafts can be done by grinding the "journals" (bearing surface on the crankshaft for the connecting rod bearings and main bearings) .010 in. (0.25 mm) or .020 in. (0.51 mm) "undersize" (smaller than the original size).The diameter of the "journals" for the connecting rod bearings is 2.7500 .0004 in. (69.850 0.010 mm). The diameter of the "journals" for the main bearings is 3.5000 .0005 in. (88.900 0.013 mm). The minimum permissible diameter of the "journals" for the connecting rods is 2.7486 in. (69.814 mm). The minimum permissible diameter of the "journals" for the main bearings is 3.4985 in. (88.862 mm). Measure each "journal" in several places around the diameter to find the maximum wear point. If the diameter of any "journal" is smaller than the minimum permissible diameter, grind all of the "journals." Before grinding a crankshaft, check the crankshaft for being straight. To check a crankshaft for being straight, support each end main bearing "journal" in V-blocks. Using a dial indicator, position the indicator at the zero reading then measure the total indicator reading at the other three main bearing "journals." The maximum total indicator reading is .006 in. (0.15 mm) at the center main bearing "journal" and .003 in. (0.08 mm) at the other two main bearing "journals." If total indicator reading is more than that given but less than .030 in. (0.76 mm) the crankshaft can be "straightened" (made straight). Before "straightening" (making straight) a crankshaft, get temperature of the crankshaft to 400° F (204° C). For the specifications for grinding a crankshaft, see the topic CRANKSHAFT GRINDING SPECIFICATIONS.With the crankshaft installed in the cylinder block, check the end play for the crankshaft. End play for the crankshaft is .006 .003 in. (0.15 0.08 mm). Maximum permissible end play for the crankshaft is .014 in. (0.36 mm). If end play for the crankshaft is more than the maximum permissible end play, check the crankshaft thrust bearing.Crankshaft Grinding Specifications
DIMENSIONS FOR GRINDING
A. Diameter of connecting rod bearing journals. B. Radius on connecting rod bearing journals. C. Width to grind journals for the connecting rods. D. Diameter of main bearing journals. E. Radius on main bearing journals. F. Width to grind journals for the main bearings.The dimensions and finish for grinding crankshafts are as follows:Diameter (A) for connecting rod bearing journals is;.010 in. (0.25 mm) Undersize ... 2.7400 .0004 in.(69.596 0.010 mm).020 in. (0.51 mm) Undersize ... 2.7300 .0004 in.(69.342 0.010 mm)Surface finish must be 10 micro inches (0.25 micrometers) or less.Radius (B) must be .100 .010 in. (2.54 0.25 mm).Surface finish must be 63 micro inches (1.6 micrometers) or less.The radius must blend smoothly with the newly machined journals.Width (C) is 2.314 +.006 -.003 in. (58.77 +0.15 -0.08 mm).Diameter (D) for main bearing journals is;.010 in. (0.25 mm) Undersize ... 3.4895 .0005 in.(88.633 0.013 mm).020 in. (0.51 mm) Undersize ... 3.4795 .0005 in.(88.378 0.013 mm)Surface finish must be 10 micro inches (0.25 micrometers) or less.Radius (E) must be .095 .010 in. (2.41 0.25 mm).Surface finish must be 63 micro inches (1.6 micrometers) or less.The radius must blend smoothly with the newly machined journals.Width (F) is 1.258 +.004 -.002 in. (31.95 +0.10 -0.05 mm) for number 4 main bearing journal. Surface finish on the thrust faces of the number 4 main must be 30 micro inches (0.75 micrometers) or less.Width (F) is 1.268 +.020 -.010 in. (32.21 +0.51 -0.25 mm) for number 2, 3, and 5 main bearing journals.There is no width (F) for number 1 main bearing journal.When grinding a crankshaft, no material can be removed from the crankshaft webs or counterweights.Crankshaft Gear Removal
Remove the gear using an 8B7548 Push Puller, 8B7551 Bearing Pulling Attachment, 8B7561 Step Plate, and 8H684 Ratchet Box Wrench.
PULLING CRANKSHAFT GEARThe 1P820 Hydraulic Puller Group can also be used to pull gear from crankshaft. Tools required are 1P820 Hydraulic Puller Group, 8B7551 Bearing Pulling Attachment, 8B7549 Puller legs (two), 8B7561 Step Plate, 3H465 Plate (four), 1B4207 Nut (two), and 9S5800 Pump Group.
USING HYDRAULIC PULLERCrankshaft Gear Installation
1. Install the key in keyway of crankshaft. Remove all burrs from key and keyway inside of crankshaft gear.2. Heat gear to 500° F. (260° C) maximum.3. Install gear on crankshaft with timing mark on gear facing front of crankshaft.Crankshaft Wear Sleeve Removal
REMOVING WEAR SLEEVEUse the 8S7164 Wear Sleeve Puller Group to remove the wear sleeve.Crankshaft Wear Sleeve Installation
WEAR SLEEVE INSTALLATION TOOLS
1. 5P290 Pilot.