7788886 Nc Engine Manual

Safety Warning This WorkshopManual will alert you to certain procedures that must be done very carefullyo if you ignore this information, you could... ® injure yourself or people around you ® injure the boat operator, boat passengers, or people around the boat ® Damagethe Volvo Penta product or its systems Understand the following Z~ Safety Warning

symbols before proceeding: Alerts you to the possibility of dangerand identifies information that will help prevent injuries. Identifies information that will help prevent damageto machinery. Appearsnext to information that controns correct assembly and operation of the product.

This WorkshopManual is written for qualified, factory trained service technicians familiar with the use of Volvo Penta special tools. This Workshop Manual reins you how to correctly maintain and service Vomvo Penta products and systems. When correctly serviced, the Volvo Penta product will be reliable and safe to operate. WhenVolvo Penta special toots are called for, use them. Where mentioned, the tools are required to perform the service procedure. if you use service proceduresor service tools that are not recommendedin this manual, YOUALONEmust decided Wf your actions might injure people or damagethe Volvo Penta product.

Contents General

information

....................

3.0 Engine 4.3,

5.7 Engines

5.0,

5.8

FL Engines

....................

5.0, 5.8 Fi Engines 7.4,

8.2 Engines

Steering

Systems

Control

Systems

Cooling

Systems

Engine Removal and Installation Safety

...........

..............................

© 1996 Volvo Penta of the Americas, Inc. All Rights Reserved

i

This Workshop Manualis oneof a set of nine that coversVolvoPenta sterndrivemodels. All ninebooks canbeorderedas a set fromVolvoPenta Parts. OrderP/N 7788880-8. IndividualWorkshop Manuals covering thesemodels are aRsoavailable.Orderthe followingpart numbers fromVolvoPentaParts. ¯ P/N 7788881-6SX, DP-SDHveUnit and Transom Shield Includes information on Transom Shield, UpperGearUnit and LowerGearUnit service; DriveUnit removalandinstallation; Propellers;andTrim,q~lthydraulic operation.

¯ P/N 77888824MRDiagnostic(5.0 F~ 5.8 Fi/FSi). Ford Includesstep by step troubleshootingprocedures for all MFIFordrelated componentsand wiring.

¯ P/N 77888832 TBI Diagnostic(4.3 Gi, 5.7 Gi/GSi)Containstroubleshootingproceduresfor all TSI GMmodelsand related components.

¯ PIN 7788884=0 MFIDiagnostic (7.4 Gi/GSi,8.2 GSi)- GN/ Includesstep by step troubleshootingproceduresfor all MFJGMrelated componentsandwiring.

¯P/N 7788885.7SP-DPDrive Unit and TransomShield Includes information on TransomShield, UpperGearUnit, LowerGearUnit service; Drive Unit removalandinstallation; Propellers;andTdm/’r~fthydraulic operationand servicing procedures.

¯ P/N 7788888=5EngineComponents Includes information on Engineservice and troubleshooting; Engineremoval andinstallation; Steeringsystems;Throttle andShift Controlsystems; andCooling systems.

¯ P/N 7788887-3 Electrical & ignition System Includesservice and troubleshootinginformation on Crankingsystems;Charging systems;Trim/Tilt electrical systems;Ignition systems;andEngineandInstrumentwiring diagrams.

¯ PiN 7788888-1Fuel System Includesservice andtroubleshootinginformationon all carburetor,MFIandTBI fuel systemsand related components.

, PiN 7788889=9DPX-LowerUnit and )(act

TM

Steering System

includes specific informationfor repair andoverhaulof the DPXLowerunit and XactTM steering systemsnot coveredin the SPand DPWorkshop manual.

This Volvo Penta WorkshopManual CoversThe FollowingVolvo Penta "NC’" Models Engine 3,0 LITER 30GSMNCA 30GSMNCS 30GSPNCA 30GSPNCS

3868181 3868181 3868182 3868182

4.3 LITER 43GLPNCA 43GLPNCS 43GLPNCB 43GSPNCA 43GSPNCS 43GSPNCM 43GSPNC8 43GSJNCS 43GSJNCC 43GiPNCACE 43GiPNCSCE 43GiPNCMCE 43GiPNCBC E

3868184 3868477 3868566 3868186 3868478 3868321 3868484 3868453 3868487 3868185 3868479 3868320 3868485

5.7 LITER 57GLPNCS 57GiPNCACE 57GiPNCSCE 57GSiPNCS

3868570 3868429 3868553 3868564

Transom Shield ..... SX-C1 SX-CLT1 SX-C1AC DP-S DPX-C

57GiPNCMCE 57GiPNCBCE 57GiINCSCE 57GiINCCCE

3868533 3868556 3868507 3868507

5.0 LITER 50FLPNCA 50FLPNCS 50FLPNCM 50FiPNCACE 50FiPNCSCE 50FiPNCMCE 50FiPNCSCE

3868414 3868414 3868419 3868416 3868416 3868421 3868421

5.8 LITER 58FLPNCA 58FLPNCS 58FLPNCM 58FLPNCB 58FLINCS 58FLINCC 58FiPNCACE 58FiPNCSCE 58FiPNCMCE 58FiPNCBCE 58FSilNCS

3868415 3868540 3868420 3868544 3868284 3868546 3868417 3868541 3868422 3868545 3868538

--- -

58FSilNCC 58FSiPNCD 58FSiPNCS 58FSiPNCACE

3868547 3868537 3868543 3868418

7.4 LATER 74GLPNCA 74GLPNCS 74GLINCS 74GLINCC 74GiPNCACE 74GiPNCSCE 74GLPNCM 74GLPNCB 74GiPNCMCE 74GiPNCBCE 74GilNCSCE 74GilNCCCE 74GSiXNCM 74GSiXNC8 74GSitNCS 74GSilNCC

3868196 3868555 3868283 3868559 3868450 3868527 3868328 3868557 3868335 3868528 3868282 3868529 3868198 3868558 3868509 3868560

8.2 UTER 82GSiXNCB

3868457

_ ............

3868404 3868432 3868515 3868299 3868289

Sterndrive SX-CT1 SX°CT1 SXoCl SX-C1 DP-S DP-S SX-C1 SX-C1

1.97:1 1.85:1 1.85:1 1.66:1 2.30:1 1.95:1 1.60:1 t .51:1

3868397 3868396 3868465 3868395 3868163 3868164 3868394 3868393

Jet Drive PJX-S PJX-C

3868467 3868694

SXoC1 DP-S DP-S SX-RT1 SX-RT1 DP-C1 DPoD1 DP-D1

1.43:1 1.78:1 1.68:t 1.66:1 2.18:1 1.95:1 1.95:1 1.78:1

3868392 3868165 3868166 3868398 3868333 3868002 872862 :3868022

DP-D1 DPX-S DPX-S1 DPX-S DPX-Sl DPX-S DPX-S1

1.68:1 1.59:1 1.59:1 1.68:1 1.68:1 1.78:1 1.78:1

3868455 3868020 3868637 3868021 3868638 3868023 3868639

Notes .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... .......................................................................................... ..........................................................................................

Section1 Generalinformation Table of Contents Belt Adjustments Alternator ........................................... Power Steering ...................................... Raw-water Pump.................................... Belt Tension ........................................ CompressionPressure Limit Chart ........................ Conversion Charts Drill ................................................ Metric .............................................. Crankcase Oil .......................................... Engine Break-in ....................................... Engine CompressionTesting ............................. Engine Troubleshooting Guides ......................... Gasolines Containing Alcohol ............................ Gasoline Requirements ................................. Introduction ............................................ Lubrication Inspection Chart ..................................... Steering System ..................................... Off-Season Storage Preparations ........................ Oil Filter ............................................. Power Steering Fluid Level ............................. PowerTrim/Tilt Fluid Level ............................... Preparation for Boating After Storage .................... SubmergedEngine .................................... Symbols .............................................. Torque Specifications, General .......................... Troubleshooting- System Isolation ...................... Tune-up Specifications ................................. Tuning the Engine ...................................... 20-Hour Check ........................................

1-24 1-22 1-24 1-21 1-7 1-40 1-39 1-9 1-18 1-5 1-26 1-8 1-8 1-2 1-42 1-11 1-11 1-10 1-11 1-11 1-17 1-20 1-41 1-38 1-25 1-33 1-5 1-20

Safety Warning Before workingon any part of any Volvo Penta® engine, read the section catled Safety at the endof this manual.

introduction This workshopmanualcovers Volvo Pentastern drive models, it is divided into sections concerning various systems and assemblies. Refer to the Contents to locate the section covering the systemor assemblyrequiring service. Each section title page has an additional listing that will describe the section’s contents in moredetail. Be sure to read the Safety Section at the end of this manual, and pay special attention to all safety warnings as they appear throughout the text. Since models are subject to changeat any time, somephotos maynot depict actual product. GoodService Practice Service required for Volvo Penta stern drives is generally one of three kinds: ®

Normalcare and maintenance-which includes putting a new stern drive into operation, storing engines, lubrication, and care under speciamoperating conditions such as salt water and cold weather.

@

Operating ma|functions - due to improper engine or drive mounting, propeller condition or size, boat condition, or the malfunction of somepart of the engine. This includes engine servicing procedures to keep the engine in prime operating condition.

e Complete disassembly and overhaul - such as major service or rebuilding a unit. It is important to determine before disassembly just whal the trouble is and howto correct it quickly, with minimumexpenseto the owner. Whenrepairing an assembly, the most reliable way to ensure a good job is to do a complete overhaul on that assembly, rather than just to replace the bad part. Wearnot readily apparent on other parts could cause malfunction soon after the repair job. Repair kits and seal kits contain all the parts neededto ensure a complete repair, to eliminate guesswork, and to save time. Repair time can also be minimized by the use of special tools. Volvo Penta speciam tools are designed to perform service procedures unique to the product that cannot be completed using tools from other sources. They also speed repair work to help achieve service flat rate times. In somecases, the use of substitute tools can damagethe part. Do not operate engine out of water even momentarily. If operated in test tank, use proper test wheel=Failure to do so can damageraw-water pump, overheat engine, or allow excessive engine RPM.

1-2

Engineleng

Preparation for Service Proper preparation is extremely helpful for efficient service work. A clean work area at the start of each job will minimize tools and parts becoming misplaced. Clean an engine that is excessiveBy dirty before work starts. Cleaning will occasionally uncover trouble sources. Obtain tools, instruments and parts neededfor the job before work is started, nnterrupting a job to Jocate special tools or repair kits is a needlessdelay. Z/~ Use proper lifting and handling equipment. Working on stern drives without proper equipmentcan cause damageand personal injury. AJwaysuse clean fresh fuel when testing engines. Troubles can often be traced to the use of old or dirty fuel Service PoJicy Whetherwithin or fonlowing the warranty period, Volvo Penta has a constant interest in their products. it is Volvo Penta’a policy to provide dealers with service knowledge so they can give professional service demandedby today’s consumer. The Volvo Penta Service Schools, frequent mailing of Service Bulletins, Letters and Promotions, Special Tools and this WorkshopManual represent Volvo Penta’s efforts to assist deal¢;rs in giving consumers the best and most prompt service possible. This WorkshopManual covers all phases of servicing the Volvo Penta stern drive unit. If a service question does not appear to be answeredin this manual, you are invited to write to the Volvo Penta Service Department for additional help. Always be sure to give complete information, including engine model number and serial number. Be sure that you are familiar with Volvo Penta’s Warranty. if you have any questions, write the Volvo Penta Service Department. If other than genuine Volvo Penta repJacement componentsor parts are used, Volvo Penta may refuse subsequent warranty claims involving that engine. Whena brand-nameproduct or specific too[ is called for, another item maybe used.. However, the substitute must have equivalent characteristics, including type, strength, and material You must determine if incorrect substitution could resuJt in product malfunction and personal injury to anyone. To avoid hazards, equivalent products which are used must meet all current U.S. Coast Guard Safety Regulations and ABYCstandards.

Replacement Parts Whenreplacementparts are required, always use genuine VolvoPentaparts, or parts with equivalentcharacteristics, including type, strength, andmaterial. Failure to do so mayresuh in productmaifiJnc~onandpossibleinjury to the operatorand/or passengers. Parts Catamogs Z~ Parts Catalogsare a goodsourceof information for ordering parts. Theyare NOTa good source for disassemblyand reassembly of the engines and drives. Theexpnododviews in the Parts Catalogsare for illustration of parts only, not a sourceof assemblyinstructions. Theworkshopmanualhas detailed informationandis the only sourceof information for disassembHy and reassembtyo Fa#ureto follow wodrshopmanualproceduresand cautions mayresult in death, personal injury to yourself or bystandersand damaged equipment. Special Service Tools

VolvoPentahas specially designedtools to simpJify disassembly andreassemblyoperations. Thesetools are illustrated in this Workshop ManualAll Volvo Penta special tools can be ordered from Volvo Penta Parts Department.Non-dealerusers of WorkshopManualsmust order Special tools through and authorized Volvo PentaDealer. ProductReferences,Illustrations andSpecifications VolvoPentareservesthe right to makechangesat anytime,without notice, to specifications, models,andprocedures.Also, the right to changeany specifications or parts at any time without incurring any obligation to equip sameon modeRs manufactured prior to date of suchchange.All information, illustrations and specifications, containedin this manualare basedon the latest productinformationavailable at the time of printing. Theright is reservedto makechangesat any time without notice. Photographs andillustrations usedin this manualmaynot depict actual modelsor equipment.The continuing accuracy of this manualcannot be guaranteed.

Safety Re|ated

1-4

Engineleng

TuningThe Engine Thepurposeof an engine tune-upis to restore powerand performancethat has beenlost throughwearanddeterioration of oneor more components.In the normal operation of an engine, these changes can take place graduallyat a number of points, it is seldom advisableto attempt improvement in performanceby correcting one or two items only. Lasting results will be obtainedby following a definite andthoroughprocedureof analysis andcorrecting all items affecting powerand performance. Economical, dependableoperation can be ensured if a complete tune up is performedonceevery boating season,preferably at the beginning of the seasonwhenboat is brought out of off season storage. Components that affect powerand performancecan be divided into three groups: e Components affecting compression eComponents affecting ignition ¯ Components affecting fuel system Proceduresfor performinga completeengine tune-up will be coveredin this manual. Engine CompressionTes~ng 1. CompressionCheck:Proper compressionis essential for good engine performance. An engine with low or unevencompression cannotbe properly tuned. &WARNING Useextremecare aroundenginewh#erunningor cranking. Remove loose clothing and jewelry to prevent entanglement with rotating pulleys and drive ~ts. a. Runengine up to normaloperating temperature. [~ Engine must NOTbe started

and run without water for

cooling.

Er,~=,~ng

~ Safety Related

1-5

b. Remove any foreign matter from aroundspark plugs by blowing out with compressed air. ~WARN~G

Wearhearing and eye protection whenusing corn pressed air

c. Remove andinspectall sparkplugs.Install thread-typecompression gaugein sparkplughole. d. To PreventSparking: ¯ 3.0GS, 4.3GL, GS, 4.3, 5.7, 7.4, 8.2Gi, andGSi Modens- remove (pink and brown) 2-wire connector from ignition coil. Onall modelsexcept 3.0 GS models, removeelectric fuel pumprelay °5.7,7.4GLw/o E.E.M.,and 8.2GL, 5.0 and 5.8 FL Models - removeboth distributor primary wires fromthe ignition coil, and tape wire terminansto prevent accidental grounding. 7.4 GL with E.E.M. Models - remove14 wire connector at the ignition module. Removeelectric fuel pumprelay. ® 5.0 and 5.8 Fi, FSi Models- Unplug 2-way connector at ignition coil. e. Withchokeandthrottle plateswideopen,crankenginethroughat least four compression strokes, Carbureted modelsonly. Test Conclusion Theindicated compression pressuresare considerednormalif the nowest readingcylinderis within 75% of the highest. Example If the highestpressurereadingwas140PSI, 75%of 140is 105. Therefore, anycylinder readingless than105PSiindicatesanimproperlyseatedvalve, wornvalveguidesor wornor brokenpiston rings. Anycylinder reading105 PSior greateris within specifications,andcompression is considered normal. If oneor morecylinders readlow, squirt approximately onetablespoonof engineoil on top of the pistonsin the low readingcylinders. Repeatcompressionpressurecheckon the cylinders. 1. If compression improves considerably, the pistonrings are at fault. 2. If compression doesnot improve,valvesare stickingor seatingpoorly,or valveguidesare worn. 3. ff twoadjacentcylindersindicate low compression pressures andsquirting oin on the pistonsdoesnot increasethe compression, the causemaybe a cylinder headgasketleak between the cylinders. Thisproblem couldallow engineoil and/orcoolantto enterthe cylinders. SafetyReJated

1-6

Engine/eng

it is recommendedthe following quick reference chart be used when checking cyninder compression pressures. The chart has been calculated so that the lowest reading number is 75%of the highest reading.

CompressionPressure Limit Chart Max. PSi

Min. PSI

Max. PSm

Min. PSI

Max. PSI

Min. PSi

Max. PSI

Min. PSI

134 136 138 140 142 144 146 148 150 152

101 102 104 105 107 108 110 111 113 114

154 156 158 160 162 164 166 168 170 172

115 117 118 120 121 123 124 126 127 129

174 176 178 180 182 184 186 188 190 192

131 132 133 135 136 138 140 141 142 144

194 196 198 2OO 202 2O4 206 208 210 212

145 147 148 150 151 153 154 156 157 158

After checking cylinder compression, repairs should be madeas necessary. Subsequent adjustments to an engine that does not have proper compression will not measurabmyimprove performanceor correct operational problems. After verifying compression, check ignition and fuel system components.

¯ Spark Plugs ¯ Spark Plug Leads e Distributor Cap ¯ Rotor ¯ ngnition Coil ¯ High Tension Lead ¯ ignition Switch ¯ Circuit Wiring and Connectors o ECM

¯ ® ¯ ¯ ¯ ¯ ® ¯ ® ¯ ¯ ¯ ®

Fuel Tank Pickup and Screen Fuel Tank Vent Anti-Siphon Valve (if equipped) Fuel Octane and Quality Boat Fuel Lines and Valves External Engine Fuel Fimter Fuel Pumpand Line Carburetor Fuel Filter or Screen Carburetor Adjustments Engine PCV"valve (if equipped) Flame Arrestor Pressure Regulator and injectors TBI Unit

All of the abovelisted componentsare not necessarily part of an engine tune-up, but must be considered when attempting to correct engine/boat performance problems. Repair or repmace componentsonly as required. Z~ Do not substitute automotive parts. Volvo Penta marine componentsmeet U.So Coast Guard reguJations for external ignition proof operation and marine use. Volvo Penta marine components are specially designednot to causeignition of fuel vapors in the bilge or engine compartment.The use of a,utomorive parts canresuKtin fire and explosion.

Eng~..;o.~ L~ Safety Related

1-7

Gasoline Requirements Volvo Penta engines are designed for maximum performanceusing gasoline with the following minimum octanespecifications: ¯ Anti-knock Index Number(AKI) ¯ Research Octane Number(RON) 4.3 GL, GSModels: Theignition timing mustbe retarded if fuels are usedwith less than 86 AKI (90 RON)octaneare used. Refer "Timing and Fuel Requirementsin the Tune Up Section of this manualfor details. Whenignition timing is retarded, a slight decrease in performancecan be expected. ,~ Use of gasoline with lower than 89AKI (93 RON)octane 4.3 modelengines, without retarding ignition timing as specified, will result in seriousdamage to your engineandwill void the engine warranty. Fuel injected Models:Every attempt should be madeto use unleadedfuel, however,somemarinasonly sell fuel with lead additives. If unleaded fuel is unavailable,the substitution of leadedfuel for temporaryuse will not harmthe fuel system. Premiumgrade fuels containinjector cleanersandother additives that protect the fuel systemand provide optimumperformance.Theuse of premium grade fuels is strongly recommended. Do not use leadedfueJ in Certified Emission engines.Leadedfuel will void the certification of emissions. CarburetedModels:Useof lead-free or leaded gasoline is acceptable. ¯

]

LN°tej Engine damageresulting from the use of gasoline with octane lower than 87 AKI (91 RON)is considered misuse of the engine and will void the engine warranty. Volvo Penta suggests the use of 89 AKI or higher fuels. Thesefuels haveadditives that are beneficial to maximum engineperformance and long life of service components.To prevent gumformation and corrosion in the fuel system, use Volvo PentaFuel SystemCleanerin the gasoline. Volvo Penta Fuel systemCleaner is available through your Volvo Pentadealer. ~ Gasoline is extremely flammable and highly explosive under certain conditions. Alwaysstop engine and do not smokeor allow openflames near the boat whenrefueling. Whenfueling, always groundthe tank to the fuel sourceby holdingthe hosenozzlefirmly againstthe side of the deckfiller plate, or groundit by someother means.This action preventsstatic electricity buildup whichcould causesparks and ignite fuel vapors.

SafetyRelated

1-8

Engine/eng

See the boat’s Operators Manual to determine if the boat’s fuel system is compatible with alcohol blended fuels. If it is, your engine may use gasolines blended with no more than 10% Ethanon (ethyl alcohol) meeting the minimumoctane specification. Do not use any gasoline which contains METHANOL I[rnethyJ alcohol). Continued use of METHANOL (methyl alcohol) fuel will cause serious damageto the boat or engine fuel systems. ff you use gasoline containing alcohol, be awareof the folk)wing: @

The engine will operate leaner. This may cause engine problems such as vapor lock, low speed stalling, or hard starting.

@

Alcohol blended fuels attract and hold moisture. Moisture can cause fuel tank corrosion. Inspect fuel tanks at least annually. Replacecorroded or leaking fuel tanks. Frequently inspect non-metallic parts of fuel system and replace if excessively stiff, deteriorated or leaking. leakage can contribute to a fire and/or explosion. DR2511

CrankcaseOil J._l~ initial factory fill is a high quality motor oil for AP! Service SG/CD.During the break-in period (20 hours), frequently check the oil level. Somewhathigher oil consumption is normal until piston rings are seated. The oil level should be maintained in the safe range between the Add and Full marks on the dipstick. This range represents approximately 1 liter (1 quart), if it is necessary to add or changethe motor oil, use a quality oil with APi service category SG/CDthat meets General Motors Standard GM-6094-M or Ford Specification ESE-M2C153-E.Volvo Penta DuraPlus TM Motor Oils are recommended. At the end of the break-in period (20 hours), changethe crankcase oil and replace the oil filter. Refer to LubricationandInspection Chart for recommendedoil change intervals, [~ The use of multi-viscosity is not recommended.

oils,

such as 10W=30or 10W-40,

Draining and Riling the Engine Crankcase Drain and refill crankcase every 100 hours of operation or once a ,season, whicheveroccurs first. Z~ To prevent fire and explosion, always make sure engine compartmentis free of gasoline fumes before using any sparkproducingtools such as the electric drill motor usedwith oil withdrawal pumpkit. Fire and explosion can result in personal injury.

[~ ""~[~ Check the motor oil frequentJy. Whenoil is to be changed,removedipstick anddrawoil from crankcasethroughdipstick tube with a suction pump.Thedipstick tube is intendedto be usedfor drainageof the engineoil so it will not haveto be drained into the bilge. Fill the crankcaseto recommended capacity with a quality motoroil labenedfor SAEservice category SGwhich meetsGeneral Motors Standard GM-6094-M or Ford Specification ESE-M2C153-E. Oils conformingto this standardcontain detergent and anti-wear additives that will prolong enginelife. Volvo Penta DuraPlusTMSynthetic Motor Off P/N 3851230-7exceedsboth manufacturersstandards.

34089

When changingmotoroil, select the viscosity that matchesthe temperature range in which the boat will be operated. Usethe same viscosity whenaddingmotoroil, do not mixdifferent viscosity oils.

I L

LowestAnticipated Temperature 32°F(0°C) and above 0°F(-18°C)to 32°F(O°C) Below0°F (-18°C)

SAEViscosity OB Recommended SAE30 SAE20W-20 SAE10W

I 341O1

~,CAUTION: Donot fill abovefull mark.Overfilling results in high operatingtemperatures,foamingthe oil (mixingair in the oil), loss of power,andreducedenginelife. CrankcaseCapacities 34164

Model 3.0 GS 4.3 GL, GS,Gi 4.3 GL, GS,Gi 2 5.0 FL 5.7 GL,Gi 5.8 FL 5.0 Fi 5.8 Fi, FSi 7.4 GL 7.4 GL3 7.4 8.2 Gi, GSi

LessFilter 3.5qts. (3,3 liters) 4.0qts. (3,8 litres) 4.5qts. (4.3 litres) 5.0qts. (4,7 litres) 5.0qts. (4,7 litres) 5.0qts. (4,7 litres) 5.0qts. (4,7 litres) 4.0qts. (3,8 litres) 5.0qts. (4,7 litres) 8.0qts. (7,8 litres) 8.0qts. (7,6 litres)

WithFilter 4.0qts. (3,8liters) 4.5 qts. (43 litres) 5.0qts. (4.7liters) 6.0qts. (5,7litres) 6.0qts, (5,7litres) 6.0qts. (5,7litres) 6.0qts. (5,7litres) 5.0qts. (4,7 litres) 6.0qts. (5,7 Witres) 9.0qts. (8,5 litres) 9.0qts. (8,5 fitres)

29712

2 with ribbed aluminum oil pan 3 with aluminumtiming chain cover

1-10

DR2497 Engme/eng

Oil Filter r~ Replace the oil filter whenever the motoroil is changed. Thisfilter is a self-contained,screw-on type. Toremove, unscrew filter canistercounterclockwise anddiscard.When attachinga newfilter, be surethe gasket is lightly lubricatedwith motoroil. Handtighten only, run engineand checkfor leaks. Donot run enginewithout supplingcoolingwater.See Tune-up Specificationsfor modelandfilter requirements. PowerSteering Ruid Level L~ [~ Maintainthe level with VolvoPentapowertrim/tilt & steering fluid. Approved powersteeringfluids suchas GMpowersteeringfluid or Dexron II automatictransmission fluid canalso be used.Donot overfill the pump reservoir.

24674

Steering SystemLubrication L~ [~ Every 60 days, greasethe steering ram ® with Volvo Penta Grease. PowerTrim/Tilt-Fluid Level

COA6781A

LL~At the beginning of eachboatingseason,checkthe fluid level in the reservoirasfollows: ~,CAUTION ¯ The trim/tilt hydraulics are pressurized whenthe drive unit is in the downposition. Thedrive unit mustbe tillted full up to relieve hydraulic pressurebefore removinglevel/fill plug ~. Failure to tilt the drive unit to the full up position beforeremoving level/fill plug wouldresult in a hazardous spray of hydraulic oil. Caution should always be taken whenremovinglevel/fill plug by placing a rag over the level/fill plug to preventresidual pressure fromsprayingoil.

3253

1. Withthedriveunit tilted full up,slowlyandcarefullyremove thelevel/fill plug. 2. Check thefluid level. Thefluid shouldbelevel withthebottom of thefill ,holewhen thedriveunit is at full tilt. If necessary, addVolvoPentapower trim/tilt &steeringfluid. Replace thelevel/fill plugandtightensecurely. Off-Season Storage Preparations 29819

,Step 1. ConditionFuelSystem: AddFuelConditioner to fuel system. Followinstructionsfor adding conditionerandrunning engine asstatedonthecontainer. Thiswill stabilizethe fuet andprevent formation of varnishandgum in entirefuel system. Dothis beforecontinuing withthefollowingprocedures. °te 1 Modelsequippedwith 4 BBLcarburetorsshouldbe run undera ~N~ loadat a highenough throttle setting to circulateconditionerthroughthe secondary fuel system. E,~+~-~ ~ Safety Related

1-1 1

199O3

Step 2- ChangeMotor Oil end Oil Fiker: Engine shouEdfirst be operated under load until oil is thoroughJy warmed up. if oil is allowed to warm up before draining, a more complete draining wile be accomplished, in addition, accumulated impurities wilJ be held in suspension by the oil and be removed during draining operation. Removemotor oil by siphoning it out of oil withdrawan tube. Follow the procedure under Draining and Filling the Engine Crankcase. Install a new oil filter and fill crankcase with recommendedoil. With drive unit in full down position, run engine at a fast idle for a few minutes to distribute clean oil through engine. Shut off engine and checkoil level. Checkoil filter gasket for leaks. Addoil if necessaryto bring oil level up to, but not over, the full mark. Drive unit must be submergedin water or an accessory flushing adaptor must be used while operating engine. Z~ Whenusing a flushing adaptor, removepropeller before starting engine to prevent accidental contact with moving propeller, if propeller is not removed,personal injury may result. Step 3. ChangeDrive Unit Lubricant: Drain and refill with fresh DuraPlussynthetic GL5gearoil. Refer to Drive Unit WorkshopManual. Step 4. Fog Engine: Carbureted and TB! Models ®

Warmup engine to ensure fuel conditioner is throughout fuel system. Use 1/~ pint (0,24 litre) of FoggingOil or oz. (355 ml) spray can to fog engine.

@

Removeflame arrestor from carburetor. Following instructions on container, bring engine up to a fast idUe and stowly pour or spray % of fogging oil into carburetor. Keep engine running whiJe pouring fogging oil into carburetor throat.

@

Rapidly add remaining I/3 of fogging oil to carburetor, then reduce throttle to idle and let engine die. Turn off ignition and replace flame arrestor. Close fuel shutoff valve (if so equipped).

Safety Related

1-12

1. Preparing anengine "storage mixture"in a six gallonfuel tank.It mustconsist of a 5 gallons (18,9liters) fuel; 4 pints(64oz., 19ml)Fogging Oil; and cup(2.5oz., 73.9ml) FuelConditioner. Mixtheseingredients thoroughly. 2. Disconnect fuel line at theengine.Connect the"storagemixture"anclrun engine for approximately 5 minutes at 1500RPM. Thiswill ensure that all fuel systems andinternal enginecomponents are thoroughlyprotected.Shutoff enginebeforethe"storagemixture"is depleted. 19efoO

~CAUTION Do not FogFi andFSi enginesthroughthe air intake. The throttle plateshavea specialcoating,fogging oil will damage thecoating. Step5. DrainCoolingSystem: ,&.CAUTION When drainingengine,raise or lowerthe bowtopositionengine in a horizontalplane.Thiswill providefor complete drainage of blockand manifolds.If bowof boatis higheror lowerthanstern, some watermaybe trappedin the engineblockor manifolds. Improper or incomplete drainingmay result in freezedamage to the engine,manifolds, driveunit or othercornponents. Freezedamage is not covered underVolvoPenta’slimited warranty°

23913

Front OLoosen andslide clampback.Remove anddrain long hoseat thermostat housing. Starboard

28288

®Disconnect andrain largehoseat circulating pump. ~.J Port ® Remove exhaustmanifoldpetcockstem.Clearhole with a smallwire to ensurecompletedrainage. ® Remove cylinder block petcockstem.Clear hole with a small wire to ensurecompletedrainage. 34093

El Front ¯ Disconnect anddrain long hoseat thermostathousing. ®Disconnect anddrainlarge hoseat circulating pump.

Disconnect the waterbypass hoseat thelargediameter endof the checkvalve. Drainor blowout check,valve andshorthoseto thermostat housing. Dra:inor blowoutlonghoseto fuel resovoir. E.Q;~e,~ 1-13

[~]

Starboard

® Loosen clamp and remove hose. ® Removecylinder block petcock stem. Clear hole with a small wire to ensurecompletedrainage, ~[]

Port

® Loosen clamp and remove hose. ® Removecylinder block petcock stem. Clear hole with a small wire to ensurecompletedrainage. |

[~

.

o

:

®e"

34O91

Q

Front

(~ Disconnect the lower water bypasshose at large diameter of check-valve. ¯

Drain or blow out check-valve and short hose to thermostat housing.

® Drain or blow out long hoseto fueJ reservoir.

[~

34102

Front

® Disconnect and drain long hose at thermostat housing. ® Disconnectan drain large hose at circulating pump. [~ Starboard 34161

® Loosen clamp and removerubber hose. Remove cylinder block petcockstem. Clear hole with small wire to ensurecompletedrainage.

1 ®1 4

Engine/eng

I~ Starboard ® Loosen hose clamp and remove rubber hose. ® Remove cylinder block petcock stem. Clear hole with a small wire to ensurecompletedrainage. r~

Port

® Loosen clamp and remove rubber hose. ® Remove cylinder block petcock stem. Clear hole with a small wire to ensurecompletedrainage.

I~

34179

Front

0 Disconnectand drain long hose at thermostat housing. ® Disconnectand drain large hoseat circulating pump.

Disconnect the water bypass hose at the large end of the checkvalve.Drain or blow out checkvalveand short hoseto thermostathousing.Drain or blowout long hoseto fuel resovior. [~ Starboard ® Loosen clamp and removerubber hose. ® Remove cylinder block petcock stem. Clear hole with a small wire to ensurecompletedrainage. [~

Port

28251

® Loosen clamp and removerubber hose. Remove cylinder block petcock stem. Clear hole with a small wire to ensurecompletedrainage.

28283

Englne/eng

1- 1 5

28284

co-

0

®® -

OnModelsequippedwith oil coolers, removelowest water hose from cooler. If cooler is mountedhorizontally, removeone water hose® from oil cooler, loosen mountingbolt ®, and tip oil cooler downward to drain. ee"

~

+

+

~

o

e_

Loosenand slide hose clamps back. Removehoses from the rear of the raw-water pumpand drain. Crank the engine no more than 2 seconds(DONOTSTART) to expel any water trapped in the raw-water pump.Reinstall raw-water pumphoses.

21122

Step 6. Drain Pivot Housing: [~] Todraincavity in pivot housing,tilt drive unit to the full tilt (up) position and removethe water drain plug @from the port side of the pivot housing.Tilt the drive unit to the full downposition. Allow unit to drain. After unit has completelydrained, replacepivot housing plug. Inspect drive unit water intake screenfor obstructions.

33857

,&CAUTION Failure to completly drain the cooling systemwill resuit in serious damage to the engine, exhaustmanifolds,andsterndrive whentemperaturego belowfreezing. If completedrainageis in doubt, checkdrain openingwith a small piece of wire. Step 8. Disconnect the Battery and place in storage. When storagewill be for a considerable lengthof time, periodically rechargethe battery following the manufacturer’s recommendations. 34087

Step9. SprayEntire EngineandDrive Unit With Volvo Penta TMCorrosionShield. Followdirections on the DuraPlus container.

1-16

Engme/eng

Preparation for Boating After Storage 11. install stemsand close all drain petcocks. Install cooling hoses and clamps. Check condition of hoses, manifold end cap,s and clamps. Connect hoses to engine and tighten clamps sec.urely. install boat drain plug, if removed. 2. Removethe distributor cap and rotor. Wipe the inside of the distributor cap dry with a clean cloth and spray with Dura Plus Corrosion Shield or equivalent. Replace the rotor and cap. 3. Clean the battery terminals. With the ignition switch in the "OFF"position, install the battery and attach the battery cables. Spray terminals with Dura Plus Corrosion Shiled or equivalent. Z~ 4. Openthe fuel shut-off valve (if fuel line connections for leaks.

so equipped) and check a|l

5. Checkthe flame arrestor and clean if necessary. Reinstall, makesure all parts are in place and tighten nut securely. 6. Makea thorough check of the boat and engine for loose or missing nuts and screws. Pumpthe bilge dry and air out the engine compartment. Safety Warning To prevent a possible explosion, operate the blower as recommended by the boat manufacturer before starting engine, if the boat is not equippedwith a bilge bllower, open engine cover or hatch prior to starting and leave openuntil after engine is running. ¯ if operating boat in water, tie boat securely to prevent forward or backward movement. Whenusing a flushing adaptor, remove the propeller before starting engine to prevent accidental contact with moving propellero if propeller is not removed, personalinjury mayresult. 7. Test run engine: Launchboat or use a flushing adaptor installed on drive unit. [~ Do not start engine out of water unless using a flushing adaptor. Always turn water on before starting engine. Control water pressure as full water pressure may cause damage to raw-water pump and engine. ~ 8. With engine compartment open, start the engine. Monitor the voltmeter, oil pressure and water temperature gauges frequently to be sure all systems are operating properly. Checkfor fuel, oiJ, and water leaks.

Engine Break-in All Volvo Penta stern drive engines have been run for a short period of time as a final test at the factory. You must follow the EngineBreak-in procedure during the first 20 hours of operation to ensure maximumperformance and longest engine Rife. To ensure proper lubrication during the break-in period, do not removefactory break-in oiU until after the 20-hour break-in is completed.

For the first five to ten minutes of operation, operate engine at a fast idle (above 1500 RPM). After engine has reached operating temperature, momentarily reduce engine speed, then increase engine speed, to assist break-in of rings and bearings. During the remaining first two hours of operation, accelerate to bring boat onto plane quickly and bring throttle back to maintain a planing attitude. During this period, vary the engine speed frequently by accelerating to approximately three-fourths throttme for two to three minutes, then back to minimumplaning speed. Maintain planing attitude to avoid excessb#eengine load. DO NOT RUN ENGINE AT A CONSTANTRPM FOR PROLONGED PERIODS OF TiME DURING THE BREAK-IN PERIOD.

During next eight hours, continue to operate at approximately three-fourths throttle or less (minimum planing speed). Occasionalty reduce throttle to idle speedfor a cooling period. During this eight hours of operation it is permissible to operate at full throttle for periods of less than two minutes. DO NOT RUN ENGINE AT A CONSTANTRPM FOR PROLONGED PERIODS OF TiME DURING THE BREAK-IN PERIOD.

During the final ten hours of break-in, after warming engine to operating temperature, it is permissible to operate at full throttle for five to ten minutes at a time. Momentarity reduce then increase engine speed to assist break-in of rings and bearings. Occasionally reduce engine speed to idle to provide cooling periods.

1 - 18

Engine/eng

DO NOT RUN ENGINE AT A CONSTANTRPM FOR PROLONGED PERIODS OF TiME DURINGTHE BREAK-IN PERIOD. During break-in period, be particularly running of engine, as follows:

observant during initial

1. Checkcrankcaseoil level frequently. Maintain oil level in safe range, between "add" and "full" marks on dipstick. if you have a problem getting a good oit level reading on dipstick, rotate dipstick 180° in tube. 2. Watchoil pressure gauge. If indicator fluctuates wheneverboat attitude (i.e. turning, climbing on plane, etc.) is changed,it may be the oil pickup screen is not covered with oil. Checkcrankcase dipstick, and add oU to crankcase if required. DONOTOVEIRFILL If oil level is correct andcondition still exists, checkfor possible gauge or oil pumpmalfunction. [~ Oia pressure will rise as RPMincreases, and fall a.,~ RPM decreases. In addition, cold oil will generally showhigher oil pressure for any specific RPMthan hot oil. Both of these conditions reflect normal engine operation. 3. Watchengine temperature indicator to be sure there is proper water circulation. Failure to follow the break-in procedure will engine warranty.

void the

At end of break-in period (20 hours}, removemotor oil and replace oil filter. Fill crankcase with recommended motor oil. Operation After Break-in After break-in, the engine can be operated at any RPMfrom idle to full throttle. However, cruising at 3600 RPMor less saves fuel, reduces noise, and prolongs engine life. Whenstarting a cold engine, always allow engine to warm up gradually. Never run engine at full throttle until engine is thoroughUywarmedup. Be sure to check oil level frequently during the first 50 hours of operation, since oil consumptionwill b,e high until piston rings are properly seated.

Submerged Engine Remove engine from water as quickly as possible. Youmu~removeall water from the engine immediatelyand lubricate all internal parts. All electrical components mustbe dried and inspectedfor ’water damage.Anydelay will allow extensiveengine damage. Frequently check engine compartmentfor gasoline fumesand excessive water accumulationin the bilge. Waterdepth in the bilge should be kept well belowthe flywheel housing.

Volvo Penta DEALER Service - 20-HourCheck 20-HourCheckincludes: 1. Change engineoil andoil filter. 2. Drainandrefill drive unit. Check the trim/tilt reservoirfor proper fluid level. Z~ 3. Lubricate steering cable ramwith Volvo Penta grease and, modelsequipped with powersteering, check pumpreservoir for correctfluid level. 5. Checkignition timing. 6. All modelsexcept MFIandTBI, checkand adjust carburetor for correct idle mixture andidle RPM. 7. Inspect exhaustsystemandtighten all hoseclamps. 8. CheckaH engine mountscrews for correct torque and engine alignment. 9. Lubricategreasefittings on transomshield (see appropriateDrive Unit Manual}.Lubricste both U-joint greasefittings on drive unit SX modelsonly. 10. Checkfor any deficiencies, malfunctions,signs of abuse,etc. Correctionof any problemsat this time will preventmajorprobJems later. 11. Change fuel filter/water separator. 12. Makesure engine can achieve maximumrated RPM. U.S., Canada,and Mexico: Boat ownerpays for the 20-HourCheck and is performedby the Volvo PentaDealer. All other markets:Seewarrantypolicy for Importers.

Safety Related

1-20

Engine/eng

Belt Tension ¯ 3.0 GSModels ® 4.3, 5.7 GL, GS,and Gi Models e 5.0, 5.8, FL andFi Models ¯ 7.4 GL, Gi, GSi and 8.2 GLModels DR4933

¯ 3.0 GSNonpowersteering Models ¯ 4.3 PJX Models ~) PowerSteering PumpBelt @) AlternatorBelt (~) Raw-waterPumpBelt EI~E~ With engine stopped, belts should be tight enough so that it will deflect 1,4" to 1/2" (6 - 13 ram)whenpressed’with finger at the point indicated. Alternate method,use Volvo Penta special tool 1159660-8 andtighten belts to 20 - 25 kg (44 - 55 Ibs.). If beJtsare too tight, excessivebelt andbearingwearcanoccur. If they are too loose, slippagecan occur, resulting in excessivebelt wear, poor circulation pump,raw-waterpump,and or powersteering performance.Tensionof a newbelt shouJdbe checkedafter 10 hoursof service andevery 50 hoursthereafter.

DR4935

DR4934

(

©

E,,gi.~/~.~

1-21

PowerSteering PumpBelt Adjustment ¯

3.0 GS Models

¯

4.3, 5.7 GL, GS, and Gi Models

¯

5.0, 5.8, FL and Fi Models

[~

®

®

¯ 7.4 GL, Gi, GSi and 8.2 GL Models [~ (~ PowerSteering PumpPulley ® Circulating PumpPulley ® 1/~,, to 1/2" (6 - 13mm)Deflection

33

i Note Improper powersteering belt adjustment will cause a loss of powersteeringassist, resulting in hard steering. [~="’~’[~ Check power steering belt tension ® midwaybetweenthe circuFating pumppulley ® and the powersteering pump pulley ~). DR4935

~] DE] To increasebelt tension: - Loosennut on lower pivot bolt, and loosen screw on brace behind pulley. Place a 1/2" breaker bar into the squarehole in the pumpmountingbracket, and pivot pumpawayfrom engine as shown. While maintaining pressure on pump,retighten all mountingscrews. Recheckbelt tension. ~CAUTION

Neverpry againstthe pump reservoiror pull filler neck. DR49~

,El~LeLl~e~,"lemicril~ ~’w4elt¯tclt ~ F~ r~ To increase belt tension: - Loosen pumpmounting bracketscrews,insert a 1/2 in. breakerbar into squarehole in the pumpmounting bracket, and pivot pumpawayfrom engine as shown.While maintainingpressureon pump,retighten all mounting screws. Recheckbelt tension. ,~CAUTION Neverpry againstthe pumpreservoir or pull filmer neck. 16O67

1-22

Engine/eng

[3-~ F’~ To increase belt tension: Loosennut on lower pivot bolt, andloosenscrewon bracebehindpulley. Placea 1/2" breaker bar into squarehole in the pumpmountingbracket and pivot pump a.way from engine as shown.While maintaining pressure on pump, retighten all mountingscrews.Recheckbelt tension. ~CAUTION Neverpry against the pumpreservoir or pull filler neck.

23910

L~ r-~ To increase belt tension: Loosenpumpmounting bracket screws. With a long pry-bar, pry against corner of timing chain cover and tab on pumpmountingbracket. While maintaining pressure on bracket, tighten screwclosest to tab. Tightenthe remaining screws. Recheckbelt tension. ACAUTION Neverpry against the pumpreservoir or pull filler neck.

24278

15930

1~901

Engineleng

1-23

Alternator Belt Adjustment ¯

3.0 GS Models

¯ 3.0 GS NPSModels o4 .3, 5.7 GL, GS, and Gi Models

[2[3 [33 [2]

e4 .3 PJX Models o5 .0, 5.8 FL and Fi Models o7 .4, 8.2 GL, Gi and GSi Models

® ® ® ®

EEl EEl

Crankshaft Pulley Circulating PumpPulley Alternator Pulley ~/~" to 1/2" (6 - 13 mm)Deflection Raw-water PumpPulley

E~,~[~ Check alternator belt tension ® midway between the circulating pumppulley ® andthe alternator pulley ®. 1. Loosenalternator mountingscrewsand nuts, pivot alternator awayfrom engineto increase belt tension. 2. Whilemaintainingtension on alternator belt, tighten top screw, bottom screw and nut. Recheckbelt tension. Thebelts usedfor the alternator, circulating pump,andpower steering pumpare heavy-duty. DONOTreplace with automotive belts. Raw- Water PumpBelt Adjustment t~e c....~,E~ Checkraw-water pumpbelt tension midwaybetween irculating pumppulley ® and the raw-water pumppulley ®. Loosenmounting bracket to raw-water pumpscrews, pry raw-water pumpawayfrom engine to increase belt tension. While maintaining pressure on raw-water pump, retighten top and bottom screws. Recheckbelt tension. 1- 24

Engine/eng

oubieshooting - SystemIsoRation The following is to help you isolate a malfunction of one or possibly several systems. After determining which systems are related to the malfunction, refer to the individual system troubleshooting charts to isolate the specific cause.

m

Engine should crank at specified for: Cranking System

RPM. If not, check

1. Discharged or dead battery 2. Loose or corroded connections 3. Cranking System Troubleshooting Chart in the Eiectri¢,,ai WorkshopManual Must have good spark at spark plugs, if not, check the:

Engine Does Not Run

1. 2. 3. 4. 5.

Distributor cap and rotor Coil and spark plug leads ignition~ timing Automatic spark advance Appropriate ignition Troubleshooting Chart in the Ignition Workshop Manual

Non-EF! Models: Carburetor accelerator pump shouRd squirt fuel into venturi whenthrottle is advanced,if not, check the: Fuel System

1. Fuel tank, valves, and lines 2. Fuel pumpand filter 3. Carburetor and filter Check the following"

Engine Runs Improperly

2. 3. 4. 5. 6. 7. 8.

Compression ignition system Fuel and carburetor/injector system Lubrication system Cooling system Drive unit and propeller Drive unit gear ratio and installation Engine Troubleshooting Guides

Engine Troubleshooting Guides Gi, GSi, Fi, FSi: Refer to the appropriatefuel injection Diagnostic Service Manual. Theseguides werewritten to help you trace the symptoms of the trouble to the source, without having to read throughand prove everypossibility. Muchof the informationherewill be familiar to well informed mechanics. Atso, manyfactors will seeminsignificant but whenyou think of it, usually the toughestproblemto troubleshootis causedby the smallest error. Thegreatest aid to solving a service problemis information. Start gathering information from the boat operator andwrite it on his job card or workticket. Find out pertinent facts, such as:

o Whendid this trouble start? o Howwas the boat loaded? e Did the trouble occur suddenly, or start gradually? Analyzethis informationandtry to matchit to similar situations you have experiencedin the past. Keepin mind the fundamental rules:

1. COMPRESSION - Mixture inducted Into cylinder and compressed. 2. SPARK - Properintensity at the propertime. 3. FUEL- Propermixture of air and fuel. Theseare very old rules, but necessaryfor the engineto run. Use these charts andthe service informationthey refer to. Donot try to remember tolerances, settings, measurements, etc., as they are written in the service manual.Leaveyour mindfree to analyze the problem. Followingis a list of the troubleshootingguides whichmaybe found on the pagesindicated. Page

Title 1. Engine Will Not Crank .............................. 2. Engine Cranks, But Will Not Start .................... 3. Hard Starting - Cold Engine ......................... 4. Hard Starting - Hot Engine ......................... 5. Engine Runs Rough ............................... 6. Engine Noises and Vibrations ........................ 7. Engine Overheats ................................. 8. Engine Dies Out ................................... 9. Engine Won’t ReachOperating RPM.................. 10. Defective Engine Lubricating System................ 11. LowBattery Voltage After Short Storage ..............

1-2~

1-27 1-27 1-28 1-28 1-29 1-29 1-30 1-31 1-31 1-32 1-32

Engine/en9

Engine Will Not Crank o

o

-

¯ e o ¯ ¯ ¯ ® ¯

Battery condition: weak, dead, sulfated, bad cells Battery cables for loose or corroded connections Shorted or open ignition switch Starter motor and solenoid for shorts, grounds or open circuits Starter assist solenoid/starter relay Circuit breakers Wiring from battery to ignition switch See Electrical/ignition WorkshopManual

Engine Cranks, But Will Not Start

e Primary circuit wiring from ignition switch to ignition coil/ignition module e Secondarycircuit wiring from coil to spark plug ¯ Spark plugs for proper gap, fouling, burned electrodes, cracked or dirty insulator ¯ See ElectricaUIgnition Workshop Manual ¯ EECpower lead attachment/relay/fuse/circuit breaker ¯ Ignition circuit breaker ¯ Low battery voltage

¯ ¯ ¯ e ¯ ¯ o ¯ o e ....

Quantity and condition of fuel in boat tank Operation and flow capacity of boat anti-siphon valve Fuel tank vent is unrestricted Fuel tank pick-up screen is clean Correct diameter/unrestricted boat fuel lines Fuel shutoff and multiple tank valves Fuel pump/relay/circuit breaker operation Fuel filter canister and carburetor filter Carburetor accelerator pump See Fuel System WorkshopManual II

=

II

0 ®

II .....

=

® Conduct test following procedure in this section, compare readings to Compression Limit Chart

and

Hard Starting - Cold Engine Ask these questions first:

¯ ® ® ®

Carburetor choke operation and adjustment Fuel lines for obstructions For debris inside fuel tank See Fuel System Workshop Manual

o ¯ o o o

For clean external canister and carburetor fuel filters Empty carburetor float bowl due to evaporation Water in fuel due to condensation Fuel quality deterioration See Fuel System Workshop Manual

o o o ¯ e

Carburetor choke operation and adjustment Carburetor accelerator pump Fuel systemfor leaks, dirt, or obstructions Engine timing and ignition system See Electrical/Ignition and Fuel SystemWorkshopManuals

Hard Starting - Hot Engine=-Ask these questions first:

® Carburetor choke operation and adjustment ® See Fuel System Workshop Manual

o o e o ¯ D Q

Brand, type or octane of fuet Spark plugs Water in fuel Condition of battery and cables Starter motor for overheat damage o

&

~

D

® Ignition system primary circuit ¯ Ignition coil/ignition module o Engine timing o Carburetor choke operation and adjustment e See Electrical/ignition and Fuel System WorkshopMan= uals

1-28

E.gi.o/~g

Engine ’

Runs 0

Rough

.....

0 " " °E~ "

¯ Idle speed and idle mixture ¯ Engine timing and spark plugs e Fuel pump pressure e Water or contaminants in fuel e Carburetor or manifold vacuum leak ® Internal carburetor fuel leak ¯ See Fuel System WorkshopManual __; ¯ ¯ ¯ ¯ ¯ ¯ ¯ ¯ ® ¯

, _ °_:_’,

.

Air leak on suction side of fuel system Too low octane fuel Ignition system secondary circuit Engine timing Wrong model or size carburetor, improper main jets or power valve, defective secondary fuel circuit, secondary vacuum diaphragm failure External canister and carburetor fuel filters Fuel pump pressure Engine compression Water or contaminants in fuel, water in cylinders See General information section and ElectricaUIgnition and Fuel System Workshop Manuals

Engine Noises and Vibrations

o Rapping only whenstarting (oil too heavy for prevailing weather, varnish on lifter, oil needs to be changed) e intermittent rapping (leakage at lifter checkball) o Idle noise (excessive leak downrate, faulty check ball seat) o Generally noisy (excessive oil in crankcase, stuck lifter plunger) e Loud noise at operating temperature (scored lifter plunger, fast leak downrate, oil viscosity too light for prevailing weather or operating temperatures) ¯ See appropriate Engine section

----

EngineNoisesand Vibrations, Cont.

¯ ¯ ¯ ¯

improper tuning incorrect spark plug wire routing Use higher octane fuel See Electrical/Ignition WorkshopManual

¯ Raw-water pump ® Loosebelts, pulleys ¯ See CoolingSystemsection

¯ Loose, broken or worn engine mounts ¯ Looselag screws holding mountsto stringer

¯ Loosebolt(s)

¯ Loosepulley, worn bearings ¯ Loose mounting bolts

e Failed U-joints or gimbal bearing e Damaged internal drive unit components ¯ Worn, bent or broken propeller hub or blades e Loose, worn or damagedengine coupler

EngineOverheats- Check: ¯ Actual enginetemperatureby verifying with an accurate thermometer ¯ Gaugeoperation and wiring circuit ¯ Sendingunit operation and wiring circuit ¯ Raw-waterpump, circulating pumpand belts ¯ Waterintake screens for blockage ¯ Thermostat ¯ Water supply hoses ¯ Engine timing e Water leaks on pressure side of raw-water pump ¯ Air leaks on suction side of raw-water pump ¯ Engine compression

1-30

E~i~g

Engine Dies Out

¯ ¯ ¯ ¯ ¯ e e e ¯ ¯ ¯ ¯ ¯

Fuel gauge operation and wiring Fuel level in tank Water or debris in fuel Fuel pickup tube and screen blockage Fuel tank vent blockage Pluggedexternal canister or carburetor fuel filters Air leak on suction side of fuel system Fuel leak on pressure side of fuel system Inoperative, restricted or incorrectly sized anti-siphon valve Boat fuel lines too small in diameter Fuel pump pressure and suction Carburetor cleanliness and operation See Fuel System WorkshopManual

~0k"F~

,ql

¯ ¯ ¯ ¯ ¯ ¯

Primary and secondary ignition circuits ignition switch Circuit breakers Wiring between engine and dash Main engine harness wiring See Electrical/ignition Workshop Manual

e e e ¯

Drive unit for internal damage Oil pressure gauge and crankcase oil level Temperature gauge and cooling system operation Internal engine components as required

Engine Won’t Reach Operating RPM- Check:, ¯ Fuel type or octane ¯ Propeller pitch or diameter, damagedblades, slipping hub ¯ Crankcase oil volume ¯ Marine growth on hull and drive ¯ Wrongdrive unit gear ratio ¯ Operating at high altitude ¯ Restricted carburetor air intake ¯ Restricted exhaust outlets in engine, transom shield or drive ¯ Poor cylinder compression ¯ Carburetor size and type correct for engine e Fuel pump pressure and vacuum e Boat overloaded, or load improperly placed e Engine overheating e Engine timing and ignition system operation ¯ Remotecontrol cables and linkage for proper attachment and travel

E~i~.~

1-31

_

~-,

Defective Engine Lubricating System _

® Cloggedor incorrect oiJ filter ® Worn oil pumpgears, cover or shaft ¯ Wornor collapsed oil pumprelief valve spring, or foreign materiam caught on valve seat ® Oil pumprenief valve plunger loose in cover ® Damagedfilter bypass grommet ¯ Clogged oil pickup screen, broken tube or housing ® Plugged crankshaft or block oil galleys ¯ Dirty or defective hydraulic lifters, clogged push rod passages ¯ Poor quality, incorrect viscosity or quantity of oil ¯ Incorrect hose routing on remote filter systems ® Water in crankcase oiU from condensation, defective head gasket, oia cooler, or cracked manifold/block water passages

¯ Oil gauge/warning horn operation and wiring ® Engine temperature o Oil pressure gauge and warning horn sender operation and wiring

LowBattery Voltage After Short Storage

e AHelectrical accessories including ignition circuit off o Disconnect main battery negative cable from battery o Connect ammeter or voltmeter in series between negative battery cable and negative battery post 1. Meter reading of "’0" indicates no draw, test battery and charging system 2. Meter movementno matter how slight indicates draw from battery ¯ Disconnect main engine harness 10-Pin Connector 1. Meter drops back to "0", problem caused by boat system, continue to isolate each boat electrical accessory untiB problem is found 2. Meter does not drop back to "0", problem caused by engine electrical system, continue to isolate each engine electrical accessory until problem is found e Repair or replace components as necessary

1-32

E~i°~t~

Tune=up Specifications

=

-- _

Engine Firing Order 3.0 GS ......................................... 4.3 GL, GS, Gi .............................. 5.0 / 5.8 FL, Fi, FSi ....................... 5.7 GL, Gi ............................... 7.4 / 8.2 GL, Gi, GSi .....................

1-3-4-2 1-6-5-4-3-2 1-3-7-2-6-5-4-8 1-8-4-3-6-5-7-2 1-8-4-3-6-5-7-2

Fuel PumpPressure All Carbureted Models ................ All Fuel Injected .................. 4.3, 5.7 Gi ...................... 5.0, 5.8 Fi, FSi .................. 7.4 Gi, GSi .....................

40-48kPa (5.75 - 7 psi) Low13,8-27,6 kPa (2-4 psi) High 62,0-89,6 kPa (9-13 psi) High 214-269 kPa (31-39 psi) High 214-269 kPa (31-39 psi)

Formore detailedinformation onfuel injection~referto pertinent Diagnostic Workshop Manuals. ForFi andFSimodels, see: MFi Diagnostic WorkshopManual(5.0 Fi, 5.8 Fi/FSi) = Ford For Gi andGSimodels see: TBI Diagnostic WorkshopManual (4.3, 5.7 Gi) MFi Diagnostic WorkshopManual (7.4, 8.2 Gi/GSi) -

Crankcase Capacities Model Less Filter 3.0 GS 3.5qts. (3,3liters) 4.0qts. (3,8litres) 4.3 GL, GS,Gi 4.5qts. (4.3litres) 4.3 GL, GS,Gi 2 5.0qts. (4,7litres) 5.0 FL 5.0 qts. (4,7 lives) 5.7 GL, Gi 5.0qts. (4,7litres) 5°8 FL 5.0qts. (4,7litres) 5.0 Fi 4.0qts. (3,8litres) 5.8 Fi, FSi 5.0qts. (4,7litres) 7.4 GL 8.0qts. (7,6 litres) 7.4 GL3 7.4 8.2 Gi, GSi 8.0qts. (7,6 litres) 2 with ribbed aluminmoil pan ~ with 41/2 raw water pumppulley

With Filter 4.0qts. (3,8liters) 4.5qts. (4.3litres) 5.0qts. (4.7liters) 6.0qts. (5,7litres) 6.0qts. (5,7litres) 6.0qts. (5,7litres) 6.0qts. (5,7litres) 5.0qts. (4,7litres) 6.0qts. (5,7litres) 9.0qts. (8,5litres) 9.0qts. (8,5litres)

Tune-upSpecifications Idle* and Operating RPM 3.0 GS Idle ...................................... WOT.................................. 4.3 GL Idle ...................................... WOT .................................. 4.3 GS Idle ...................................... WOT .................................. 4.3 Gi Idle ........................... WOT.................................. 5.0 FL Idle ...................................... WOT.................................. 5.0 Fi Idle ........................... WOT.................................. 5.7 GL Idle ...................................... WOT.................................. 5.7 Gi Idle ........................... WOT.................................. 5.8 FL idle ...................................... WOT.................................. 5.8 Fi Idle ........................... WOT....................................... 5.8 FSi Idle ........................... WOT....................................... 7.4 GL Idle ...................................... WOT ....................................... 7.4 Gi Idle ........................... WOT ....................................... 7.4 GSi Idle ........................... WOT ....................................... 8.2 GL Idle ...................................... WOT .................................. 8.2 GSi Idle ........................... WOT................................. * In Forward Gear WOT= Wide Open Throttle

650-750 4200-4600

RPM RPM

550-650 4200-4600

RPM RPM

550-650 4400-4800

RPM RPM

600 RPM- Not Adjustable 4400-4800 RPM 550-650 4200-4600

RPM RPM

600 RPM- Not Adjustable 4200-4600 RPM 550-650 4200-4800

RPM RPM

600 RPM- Not Adjustable 4200-4600 RPM 550-650 4000-4400

RPM RPM

800 RPM- Not Adjustable 4200-4600 600 RPM- Not Adjustable 4600-5000 550-650 RPM 4200-4600 600 RPM- Not Adjustable 4200-4600 600 RPM- Not Adjustable 4800-5200 550-650 4400-4800

RPM RPM

600 RPM- Not Adjustable 4600 - 5000 RPM

Tune-upSpecifications ~

r Distributor Specifications

:3.0 GS Sensor Air Gap .......... N/A - De/co® EST ignition system Distributor Rotation ........................... clockwise 4.3 GL, OS,Oi Sensor Air Gap .......... N/A - DeJco®EST ignition system Distributor Rotation ........................... clockwise 5.0 FL Sensor Air Gap .................... 0.008 inch (0,203 mm) Distributor Rotation .................... counter-clockwise 5.0 Fi Sensor Air Gap ......... N/A- Ford TFI-IV® ignition system Distributor Rotation .................... counter-clockwise 5.7 Gi N/A - Delco® EST ignition system Sensor Air Gap .......... Distributor Rotation ........................... clockwise 5.8 FL Sensor Air Gap .................... 0.008 inch (0,203 mm) Distributor Rotation .................... counterclockwise 5.8 Fi, FSi Sensor Air Gap ......... N/A - Ford TFI-IV® ignition system Distributor Rotation .................... counter-clockwise 5.7, 7.4", 8.2 GL Sensor Air Gap .................... 0.008 inch (0,203 mm) Distributor Rotation ............................ clockwise 7.4, 8.2 Gi, GSi Sensor Air Gap .......... N/A - De~co®EST ignition system Distributor Rotation ............................ clockwise 8.2 GL SensorAir Gap .................... 0.008 inch (0,203 ram) Distributor Rotation ........................... clockwise * Without Volvo Penta E.E.M. system. For information on Volvo Penta E.E.M. see Electrical & Ignition WorkshopManual P/N 7788887-3

Oil Pressure- All Models 800 RPM............................ 2000 RPM ...........................

103-207 kPa (15-30 psi)j 276-414 kP~L (40-60 ps~)j

¯

Tune-up Specifications Spark Plugs 3.0 GS Spark Ptug ................. VP-3851857-7, AC-MR43LTS,CH-RS12YC Gap ............................................ 0.045" (1,143 mm) Torque ............................................ 20 ft. lb. (27Nm) 4.3 GL, GS Spark Plugs ................ VP-3851859-3, AC-MR43LTS,CH-RS12YC Gap ............................................ 0.045" (1,143 mm) Torque ............................................ 20 ft. lb. (27Nm) 4.3 Gi Spark Plugs ................ VP-3851859-3, AC-MR43TS, CH-RV15YC4 Gap ............................................ 0.045" (1,143 ram) Torque ............................................ 20 ft. lb. (27Nm) *4.3 GL, GS, Gi Spark PJugs ................ VP-3856756-0, AC-MR43LTS,CH-RS12YC Gap ............................................ 0.045" (1,143 ram) Torque ............................................ 20 ft. lb. (27Nm) 5.0 FL Spark Plugs ................ VP-3851861-9, MC-ASF32C, CH-RV15YC4 Gap ............................................. 0.035"(0.889 mm) Torque ..................................... 5-10 ft. tb. (6.7-13.5 Nm) 5.0 Fi Spark Plugs ............... VP-3851857-7, MC-AWSF32C,CH-RS12YC Gap .............................................. 0.045"(1.14 ram) Torque ..................................... 5-10 ft. lb. (6.7-13.5 Nm) 5.7 GL Spark Plugs ................. VP-3851859-3, AC-MR43T,CH-RV15YC4 Gap .............................................. 0.035" (0.89mm) Torque ............................................ 20 ft. lb. (27Nm) 5.7 Gi Spark Plugs ................. VP-385t862-1, AC-R43TS, CH-RV15YC4 Gap ............................................ 0.045" (1,143 ram) Torque ............................................ 20 ft. lb. (27Nm) 5.8 FL Spark Plugs ................ VP-3851861-9, MC-ASF32C, CH-RV15YC4 Gap ............................................ 0.035" (0,889 mm) Torque ..................................... 5-10 ft. lb. (6.7-13.5 Nm) 5.8 Fi, FSi Spark Plugs ................ VP-3851888-4, MC-AWSF22C,CH-RS9YC Gap .............................................. 0.045"(1.14 mm) 5-10 ft. lb. (6.7-13.5 Nm) Torque ..................................... 7.4 GL Spark Plugs ................. VP-3851861-9, AC-MR43T, CH-RV15YC4 Gap ............................................ 0.045" (1,143 mm) Torque ............................................ 20 ft. Jb. (27Nm) 7.4 Gi Spark Plugs ................. VP-3851862-1, AC-R43TS, CH-RV15YC4 Gap ............................................ 0.045" (1,143 mm) Torque ............................................ 20 ft. lb. (27Nm) 7.4 GSi Spark Plugs ................. VP-3851861-9, AC-MR43T,CH-RV15YC4 Gap ............................................ 0.045" (1,143 mm) Torque ............................................ 20 ft. lb. (27Nm) 8.2 GSi Spark Plugs ................. VP-3851861-9, AC-MR43T, CH-RV15YC4 Gap ............................................ 0.045" (1,143 mm) Torque ............................................ 20 ft. lb. (27Nm) *With ribbed aluminumoil pan VP = Volvo Penta CH = Champion AC = AC Delco MC= Motorcraft 1-36

Engine/eng

Tune-up Specifications Timing and Fuel Requirements 3.0 GS ......................

0° TDC- w/87 AKI or higher Volvo Pema885163-6 shunt required

4.3 GL, GS..................

0° TDC- w/89 AKI or higher 5° ATDC- w/87 AKI Volvo Penta 885163-6shunt required

4.3GL, GS* . ...............

°BTDC-w/89AKIorhigher 6 1 ° BTDC- w/87 AKI Volvo Penta 885163-6shunt required

4.3 Gi ......................

8° BTDC- w/87 AKI or higher Service Moderequired

5.7 GL .....................

8° BTDC- w/86 AKI or higher

5.7 Gi ......................

8° BTDC- w/87 AKI or higher Service Moderequired

5.0 FL ....................

10° BTDC- w/86 AKI or higher

5.8 FL ....................

10° BTDC- w/86 AKI or higher

5.0 Fi .......................

5° BTDC- SPOUTremoved

5.8 Fi, FSi ...................

5° BTDC- SPOUTremoved 10° BTDC- w/89 AKI or higher 6° BTDCw/87 AKI or higher

7.4 GL .................... 7.4 GL w/E.E.M ...............

10° BTDC- Non Adjustable w/86 AKI or higher

7.4 Gi .....................

10° BTDC- w/87 AKI or higher Service Moderequired

7.4 GSi ...................

10° BTDC- w/87 AKI or higher Service Moderequired

8.2 GL ............. 8.2 GSi ...................

~ .......

8° BTDC- w/89 AKI or higher 3° BTDC- w/87 AKI or higher 10° BTDC- w/87 AKI or higher Service Moderequired

E.E.M. = Volvo Penta Electronic EngineManagement *with ribbed, aluminum oil pan

METRIC CONVERSIONCHART inches feet yards miles inches

X X X X X

25.4 0°3O48 0.9144 1.6093 2.54

= millimetres (ram) = metres {m) = metres (m) = kilometres (kin) = centimetres (cm)

W

X 1.3558 X 4.187 X 1055 X 3500 X 3.600

= joules (j) = joules {j) = joules {j) = joules(j) = megajoules(M J)

| =|J:lib=It[el~[=]Fjlh’N-~ ~I =It;L|J=lIKEe] ~[~’~JJ Lv~l’ji i [=]~|

= inches 2 inches = feet = yards acres

X X X X X

zmiles

X 2.590

= millimetres= =) (ram = centimetres= 2) (cm = metres= =) (m =) = metres= (m = hectares (104 2) (ha) = =) = kilometres (kin

3 inches 3 inches 3 inches quarts gallons zfeet ~ feet fluid oz 3 yards

X X X X X X X X X

16387 16.387 0,01639 0.94635 3.7854 28.317 0.02832 29.57 0.7646

= millimetres3 z) (ram 3) = centimetres3 (cm = litres (I) = litres (I) = litres (I) = litres (I) = metres3 3) (m = miliilitres (ml) = metres3 3) (m

ounces (av)

X X X X

28.35 0.4536 907.18 0.90718

= grams (g) = kilograms (kg) = kilograms (kg) = metric tons (t)

pounds(av) tons (2000Ib) tons (2000Ib)

foot-pounds calories Btu watt-hours kilowatt - hrs

645.16 6.452 0.0929 0.8361 0.4047

[FORCE

ounces - f (av) X 0.278 pounds- f (av) X 4.448 kilograms- f X 9.807

= newtons (N) = newtons (N) = newtons (N)

2 feeUsec 2 inches/sec

= 2) = metres/see (m/S = (m/S 2) = metres/sec

X 0,3048 X 0.0254

miles/gal

X 0.42514= kilometres/litre

(km/I)

Note: 235.2/(mi/gal) = litres/100 235.2/(litres/100 km)= mi/gal

footcandles e

X 10.76 Q=

2 =) = lumens/metre (Um/m

o

= kilopascals (kPa) = kilopasca|s (kPa) = kilopascals (kPa) = kilopascals (kPa) = pascals (Pa)

inches HG(60°F) pounds/sqin inches HsO(60°F) bars pounds/sqft

X 3.377 X 6.895 X 0.2488 X 100 X 47,88

horsepower ft-lbf/min

X 0.746 = kilowatts (kW) X 0.0226 = watts {W)

°Celsius = 0.556X (°F -32) °Fahrenheit = (1.8 X °C) +32

pound-inches pound-feet

X 0.11299 = newton-metres (N.m) X 1.3558 = newton-metres (N-m)

miles/hour feet/sec kilometres/hr miles/hour

X X X X

1-38

1.6093 = 0.3048 = 0.27778 = 0.4470 =

kiiometres/hour(kin/h) metres/sec(m/s) metres/sec(m/s) metres/sec(m/s)

Engine/eng

Drill Size ConversionChart

DR2949

SHOWING MILLIMETERSIZES, FRACTIONALAND DECIMALiNCH SIZES ANDNUMBER DRILL SIZES Dec. FracMilli- Dec. Frac- Num- Milli- Dec. Frac- Num- Milli- Dec. Frac- Num-MilliDec. Frac- Num-MilliMeter Equiv. tional bet Meter Equiv. tional Meter Equiv. tional ber Meter Equiv. tional ber Meter Equiv. tional ber .1 .0039 .15 .0059 .2 .0079 .25 .0098 .3 .0118 .... 0135 .35 .0138 .... 0415 .39 .0156 .4 .0157 .... 0160 .45 .0177 .... 0180 .5 .0197 .... 0200 .... 0210 .55 .0217 .... 0225 .6 .0236 .... 0240 .... 0250 .65 .0256 .... 0260 .... 0280 .7 .0276 .... 0292 .75 .0295 .... 0310 .79 .0312 .8 .0315 .... 0320 .... 0330 .85 .0335 .... 0350 .9 .0354 .... 0360 .... 0370 .95 .0374 .... 0380 .... 0390 1.0 .0394 .... 0400 .... 0410 .05 .0413 .... 0420 .... 0430 1.1 .0433 1.15 .0452 .... 0465 1.19 .0469 1.2 .0472 1.25 .0492 1.3 .0512 .... 0520 1.35 .0513 .... 0550 1.4 .0551 .45 .0570 1.5 .0591 .... 0595 .55 .0610 .59 .0625 1.6 .0629 .... 0635 1.65 .0649 .7 .0669 .... 0670

80 %4

79 ... 78 77 76 75 74 73 72 71 70 69

½2

68 .., 67 66 65 64 63 62 61 60 59 58 57

¥64

56 ...

55 54

53 ¼6

... 52 51

1.75 .0689 .... 0700 1.8 .0709 1.85 .0728 .... 0730 t.9 .0748 .... 0760 1.95 .0767 1.98 .0781 .... 0785 2.0 .0787 2.05 .0807 .... 0810 .... 0820 2.1 .0827 2.15 .0846 .... 0860 2.2 .0866 2.25 .0855 .... 9890 2.3 .0905 2,35 .0925 .... 0935 2.38 .0937 2.4 .0945 .... 0960 2.45 .0964 .... 0980 2.5 .0984 .... 0995 .... 1015 2.6 .1024 .... 1040 2.7 .1063 .... 1065 2.75 .1082 2.78 .1094 .... 1100 2.8 .1102 .... II10 .... 1130 2.9 .1141 .... 1160 3.0 .1181 .... t200 3.1 .1220 3.18 .1250 3.2 .1260 3.25 .1279 .... 1285 3.3 .1299 3.4 .1338 .... 1360 3.5 .1378 .... 1405 3.57 .1406 3.6 .1417 .... 1440 3.7 .1457 .... 1470 3.75 .1476 .... 1495 3.8 .1496 .... 1520 3.9 .1535 .... 1540 3.97 .1562

.... 1570 4.0 .1575 .... 1590 .... 1610 49 4.1 .1614 4.2 .1654 48 .... 1660 4.25 .1673 %4 ... 4.3 .1693 47 .... 1695 4.37 .1719 11/~ .... 1730 46 4.4 .1732 45 .... t770 4.5 .1771 .... 1800 44 4.6 .1811 .... 1820 4.7 .1850 43 4,75 .1870 4.76 .1875 ~9 4.8 .1890 42 .... 1910 ~2 ... 4.9 .1929 .... 1935 41 .... 1960 5.0 .1968 40 .... 1990 5.1 .2008 39 .... 2010 38 5.16 .2031 1~4 .... 2040 37 5.2 .2047 .... 2055 36 5.25 .2067 5.3 .2086 %4 ....... 2090 35 5.4 .2126 ..... 2130 34 5.5 .2165 33 5.56 .2187 7,~z 5.6 .2205 .... 2210 32 5,7 .2244 31 5.75 .2263 .... 2280 ~ ... 5.8 .2283 5.9 .2323 .... 2340 30 5.95 .2344 lS/~ 6.0 .2362 .... 2380 29 6.1 .2401 .... 2420 28 6.2 .2441 %4 ... 6.25 .2460 6.3 .2480 27 6.35 .2500i/,= 6.4 .2520 26 6.5 .2559 .... 2570 25 6.6 .2598 .2610 24 6.7 .2638 6.75 .2657 1%4 23 6.75 .2657 ~ .,. .... 2660

22

50

21 20 19 18 1’7" 16 15 14 13 12 11 10 9 8 7 9i

6 5 4 3 .. . 2 1 A ... B C D E F G ... H

6.8 .2677 6,9 .2716 .2720 7.0 .2756 .... 2770 7.1 .2795 .... 2811 7.14 .2812 %2 7.2 .2835 7.25 .2854 7.3 .2874 .... 2900 7.4 .2913 .... 2950 7.5 .2953 7.54 .2968 19/s4 7.6 .2992 ..... 3020 7.7 .30311 7.75 .3051! 7.8 .3071, 7.9 .3110 7.94 .3125 ~16 8.0 .3150 .... 3160 8.1 .3189 8.2 .3228 .... 3230 8.25 .324~| 8.3 .3268 8.33 .3281 21/r~ 8.4 .3307 .... 3320 8.5 .3346 8.6 .3386 .... 3390 8.7 .3425 8.73 .3437 "~. 8.75 .3445 8.8 .3465 .... 3480 8.9 .3504 9.0 .3543 .... 3580 9,1 .3583 9.13 .3594 23/64 9,2 .362;! 9.25.36411 9.3 .36611 .... 3680 9.4 .37011 9.5 .3740 9.53 .3750 3/9 .... 3770 9.6 .3780 9.7 .3819 9.75 .3838 9.8 .3858 .... 3860 9.9 ,.3839 9.92 .3906 2%4 10.0 .3937 .... 3970 .... 4040 10.32 .4062 1¥32 .... 413(I 10.5 .4134

I J K .. .

L M ... N

,.. O P . .. Q R .. . S T ...

U . .. V

W .. . X Y .. . Z

10.72 .4219 27/64 11.0 .4330 11.11 .4375 7/re 11.5 .4528 11.51 .4531 2%4 11.91 .4687 ls/32 12.0 .4724 12.30 .4843 sl/~ 12.5 .4921 12.7 .5000 1/2 13.0 ,5118 13.10 .5156 3~’64 13.49 .5312 17/32 13.5 ,5315 13.89 .5469 3%4 14.0 .5512 14.29 3624 9Ae 14.5 .5709 14.68 .5781 3%4 15.0 .5906 15.08 .5937 W3z 15.48 .6094 39/~ 15.5 .6102 15.88 .6250 9h 16.0 ,6299 16.27 .6406 41/e4 16.5 .6496 16.67 ,6562 21/32 17.0 .6693 17,06 ,6719 4%4 17.46 ,6875 11/lS 17.5 3890 17.86 .7031 45/64 18,0 .7087 18.26 .7187 =%2 18.5 .7283 18.65 .7344 47/~ 19.0 ,7480 19.05 .7500 3/4 19.45 .7656 4%4 19.5 .7677 19,84 ,7812 2%z 20.0 .7874 20.24 .7969 sl/~ 20.5 .8071 20.64 .8125 13/le 21.0 .8268 21.04 .8218 5~ 21.43 .8437 27/.~ 21,5 3465 21,83 .8594 5%4 22.0 .8661 22.23 .8750 7/9 22.5 .8858 22.82 .8906 sT/e4 23.0 .9055 23.02 .9062 2%2 23.42 .9219 s%4 23.5 .9252 23.81 .9375 15/16 24,0 .9449 24.21 .9531 9V~ 24.5 .9646 24.61 .9687 zl/32 25,0 .9843 25.03 .9844 93/94 25.4 1.0000 1 DR2949-ENG

SYMBOLS Certain symbolsor combinations of symbolsmayappear on your Volvo Penta stern drive or on its accessories, it is very important that you understandtheir meaningor purpose,ff any symbolis not clearly understood,see your DeaJer.

"Safety Warning" Symbols

Fire hazard Contents under pressure

"Position indicator" Symbols Shift positions NEUTRAL

im®.~

LOWER

RAISE

FORWARD

REVERSE

"Condition" Symbols ¯ Voltmeter ¯ Ammeter

Hour meter

Voltmeter

Emergency stop

"instructional"

~

Tachometer

Fuelfilter

Oil filter

Watertern peratu re

¯ Use gasoline ¯ Gasoline is present

G ’~Oil

pressure

Symbols

Read Operator’s Manual before operating product

Oilfill DR3847

Englne/eng

’i

-40

Lubrication and Inspection Chart items marked~ Safety Warningare safety related service points to prevent mechanicalfailures, fire and explosion. Makesure the safety related service is pertFormedat these points and at the intervals specified.

Service Point

20-Hour Check

Every 100 Hours or as Specified

Recommendations

Alternator Belt, Powor Steering PumpBelt

Check and tighten

Checkbelt for ten~,ion and deterioration.

Adjust tension to specifications. Replacedeteriorated belt. Keepspare on board.

Checkfor damageto grill area. Must be firmly attached,

Seasonallyclean end inspect. Damaged unit may allow backfire flame to enter engine compartment,

If damaged,replace with specified VolvoPentaparts. If dirty, clean in solvent, end air dry before installation.

Crankcase

Checkoil level dally,

Drain and refill ew~ry100 hours or once a season, whichever comes first.

Seespecifications.

Engine Alignment

Check

Seasonally

Check engine alignment.

Oil Filter

Replace

Replace

Seespecifications.

Service Point

20-Hour Check

Every 100 Hours or as Specified

Recommendations

Power Steering Pump

Checkreservoir fluid level

Steering Cable Ram

Checkand lubricate

Flame Arrestor

Safety Related

Checkreservoir flLiid ]eve[.

Use Vo/vo Penta powertrim/tilt steering fluid.

&

Lubricate every 50 hours or every 60 Use Volvo Penta Grease. days, whichevercomesfirst.

1-41

Engine/eng

Lubrication and inspection Chart - Continued

Service Point

20J-lout Check

Every 100 Hours or aa SpeciRed

Recomme~latfen$

Engine

Checkfor leaks. Check belts for correct tension.

Seasonally check for hose deterioration. Volvo Penta SX, check raw-water pumpoperation. Repair as required.

Drain after operation in freezing temperatures, or during seasorml lay up. Tighten connections. Re|01ace raw-water pumpimpeller every 2 years.

Seasonally check for hose deterioretiono

Drain after operation in freezing temperatures, or during seasonal lay up. Drain after operation in freezing temperatures, or during seasonallay up.

TransomShield Check water pickup screensfor obstructions. Replaceoil.

Reptecegear oil avery 100 hours or

Drive Unit

Service Point

20-Hour Check

Every 100 Hours or as Specified

Control Linkage

Check operation. Check adjustmentand lubricate.

Shift Systsm

Service Point

Bilge Area Hull

ORC6 a season.

Adjust as required. Use Volvo Penta Grease.

Checkfor smoothshifting in and out of forward and reverse gears,

Seasonelly or every 100 hours, checkcable and shift assist for proper operation.

Replaceshift cable if necessary.

20-Hour Check

Every 100 Hours or aa Specified

Recommendations

Checkfor fuel fumesand leaks,

Repair or replace defective components.

Check for marine growth.

Clean boat bottom. See Preparation for Boat6ng.

Preparation for Boating Season Safety Equipment

Recommendations

Check remote control and emergencystop switch, if equipped, for proper operation.

All boat safety equipmentshould be checkedfor condition and proper operation,

Be sure you have U.S.CoG.required equipment aboard (check Coaat Guard regulations)o See Off-Season Storage.

Storage Secsonslly repack wheel bearings.

Trailer

Safety Related

1-42

Use Wheel Beadng Grease.

Engine/eng

Section 2

3.0 GS Volvo Penta Engine Table of Contents Camshaft .......................... Camshaft Bearings .................. Circulating Pump .................... Connecting Rod Bearings ............. Crankshaft ......................... Crankshaft Bearings ................. Cylinder Block ...................... Cylinder Head Assembly .............. Distributor Lower Bearing ............. Engine Coupler Replacement ........... Engine Specifications ................. Exhaust (Flapper) Valve Replacement .... Exhaust Hose Replacement ............ Front Engine Mount .................. Height Adjustment .................

2-14 2-16 2-32 2-19 2-18 2-20 2-27 2-6 2-31 2-40 2-42 2-39 2-38 2-35 2-37

High.Rise Exhaust Elbow Replacement... 2-37 Hydraulic Valve Lifter ................. 2-4 Intake/Exhaust Manifold .............. 2-3 Oil Filter By-Pass Valve ............... 2-35 Oil Pan Replacement ................. 2-32 Oil Pump .......................... 2-33 Oil Seal, Rear Main Bearing Replacement 2-23 Oil Seal Retainer Replacement ......... 2-23 Piston Rings ........................ 2-25 Pisten and Connecting Rod ............ 2-23 Timi~g Gear Cover ................... 2-12 Torque Specifications ................. 2-45 Valve Lash Adjustment ............... 2-5 Va|ve Spring and Seal Repair ........... 2-6

Before removing cooling system hoses, it may be necessary to removeboat from water to prevent flooding boat.

Safety Warnings Before working on any part of the engine, read the section called Safety at the end of this manual. Unless instructed otherwise, always disconnect the battery cables from the battery before workin!;] on electrical system to prevent possible sparks or arcing in the engine compartment. Before starting engine after repair or maintenance procedures, always make sure engine compartment is free of fue~ vapors to prevent possible fire and explosion. Whenworking on an engine that is running or being cranked, use extreme care to avoid getting hands, fingers or clothing caught in the alternator, power steering, raw-water pumparid circulating pumpbelts, pulleys and other moving parts.

Genera/Motors Tools item

Part Number

Air Line Adaptor .............................. Bolt Guide Set .............................. Cam Lobe Lift Indicator .......................... Camshaft Bearing Remover and Installer .......... Carbon Remover Brush .......................... Crankshaft Gear Installer ......................... Cylinder Bore Checker ........................... Distributor Bearing Installer ....................... Distributor Bearing Remover ................... Piston Pin Tool ................................ Piston Ring Tool ............................... Rear Crankshaft Seal Installer .................... Rocker Arm Stud Hole Reamer(0.003 Oversize) ....... Rocker Arm Stud Hole Reamer(0.013 Oversize) ....... Rocker Arm Stud Installer ........................ Rocker Arm Stu6 Remover ..................... Timing Cover Tool ............................. Valve Guide Cleaner ............................ Valve Guide Reamer Set ....................... Valve Seal Tester .............................. Valve Spring Compressor ........................ Valve Spring Compressor ........................ ’Valve Spring Tester ............................. Vibration Damperand Crankshaft Gear Remover .....

J-23590 J-6305-01 J-8520 J-6098-01 J-808g J-5590 J-8087 J-9535 J-9534-01 J-24086 J-8037 J-35621 J-5715 J-6036 J-6880 J-5802-01 J-23042 J-8101 J-5830-02 J-23994 J-5892 J-8062 J-8056 J-6978-E

Order Directly from: Kent-Moore Tool Division 28635 Mound Road Warren, MI 48092 800-345-2233 Price and ordering information Tool Division.

are available

from Kent-Moore

Material Required Molykote Lubricant Gasket Sealing Compound Permatex No. 2 GMSuper Engine Oil Supplement Plastigage (Green) DuraPlus Synthetic Motor Oil or Equivalent For additional service information not covered in this manual, obtain the appropriate Chevrolet Engine WorkshopManual from: Helm Inc. P. O. Box 07130 Detroit, MI 48207

2-2

Engineleng

Intake/Exhaust Manifold RemovaJ ,~ 1. Disconnect battery cables at battery. Removethrottle ,cable from anchorblock and actuating bracket. 2. Drain water from block and exhaust manifold (see C~)oling System Section in this manual). 3. Removecarburetor from intake manifold. Follow the instructions in Fuel SystemsWorkshopManual.

34734

I~] 4. Disconnect water hoses (~) and ® running between manifold end cap and thermostat housing, and thermostal; housing and power steering cooler or transom shield. 5. Power Steering Models: Removealternator ,cooler and mountingplate (~}).

©, and oil

[~ 6. Loosen upper hose clamps ~) securing exhaust hose to high rise elbow. Loosen and remove screws and lock wasl~ers ® securing elbow to manifold and removethe throttle linkage plate and elbow.

22479

7. Remove four bolts, two nuts and lock washers securing manifold to cylinder head, then pull manifold off of head. Discard gasket. 8. Clean all gasket surfaces of cylinder head and manifold and check for cracks on the manifold casting. Installation 1. Position a newgasket over the manifold studs on the head. Use a gasket sealer if leakage has occurred. Carefully install the manifold in position making sure that the gasket is correctly placed. 2. install nuts, bolts and washers while holding the manifold in place. Tighten bolts and nuts finger tight, then alternately 1lighten to 20-25 ft. Ibs. (27-34 N-m) working from the center towards the ends. 3. Apply gasket sealer to a new elbow gasket and place it on the manifold. Push the elbow into the exhaust hose, then install the elbow, throttle linkage plate, lock washers, and screws. Tighten the screws to 12-14 ft. Ibs. (16-19 N-m). [~ 4. Install carburetor using a new mounting gasket following the instructions in Fuel SystemsWorkshop Manual. Install water hoses from thermostat housing to manifold ~), and transom shield or power steering cooler to thermostat ®.

34727

5. Power steering models: InstalU alternator, mounting plate.

oil

cooJer and

6. Reconnect throttle cable to anchor block and actuating bracket. Securewith cotter pin. Z~ 7. Connectbattery cables. Start engine and check for fuel leaks.

HydraulicValveLifter

1. With air hose and cloths, clean dirt from cylinder head and adjacent parts to avoid getting dirt into engine, it is extremely important’that no dirt gets into the valve lifters. 2. Disconnect ventilation hose, fuel line, and fueJ pumpoverflow hose. Removecircuit breaker bracket. Removerocker arm cover. 3. Loosen rocker arm nuts and pivot the rocker arms free of the push rods. 4. Disconnect spark plug wires at plugs. Removehigh tension mead from coil. Removeboth connectors from coil. Removecoil and mounting bracket from cylinder head.

22477

El: 5. Removeboth connectors at distributor. Take off cap, note distributor rotor position and removedistributor. (Mark distributor housing and block with chalk at point of rotor.) 8. Removepush rod cover and gasket.

ROTA33NG - NORMAL, OK- NOTROTATING

7. Remove push rods and lift out valve lifters that require service. Place lifters in a woodenblock having numbered holes, or use other suitable meansof identifying them according to original position in the engine. 8. If less than a complete set of lifters is being removed,immediately disassemble and inspect one or two for presence of dirt or varnish. If Hfters contain dirt or varnish, it is advisable to replace all lifters. Otherwise, it will be satisfactory to service only those lifters that are not operating properly.

LLED - SHOULD BE REPLACED - SOFT, WORN

[~ 9. Examine the cam contact surface at lower end of lifter body. if this surface is excessively worn, galmed or otherwise damaged,discard the lifter assembly, in this case, also examine the mating camshaft lobe for excessive wear or damage.

Safety Related

2-4

Engine/eng

Insta||ation 1~ Before installing any new lifters, lifter with Molykoteor its equivalent.

coat the bottom of each

1. install valve lifters in cylinder block. If anynewlifters or a new camshaft has been installed, an additive containing EP lubricant such as GM Engine Oil Supplement must be added to the crankcaseoil for break-in. 2. install pushrods onto lifters new gasket.

and install

push rod cover with a

:3. install distributor (position rotor to markon housingand block). LnstaHcoil and bracket. Connectboth connectors to coil. Install distributor cap and attach spark plug and coil wires. Connectboth connectors to distributor. 4. Install shift bracket assembly. 5. Pivot rocker arms in place and turn adjusting nuts the amount necessary to eliminate lash.

Valve Lash Adjustment Adjust valve lash whenlifter

is on base circle of camas follows:

1. Remove distributor cap and crank engine until distributor rotor points to numberone cylinder terminal, in this position the piston in number one cylinder is at top dead center on compression stroke. Both lifters are on base circle of camand both valves can be adjusted. i~] 2. Turn adjusting nut until all lash is removedfrom valve train. This can be determined by checking push rod side play by hand while turning nut slowly. At this point, turn adjusting nut one moreturn to place the lifter plunger in center of its travel. 3. Follow steps 1 and 2 for each cylinder following firing order sequenceand adjust remaining valve one cylinder at a time. No further adjustment is necessary. !~ Do not attempt to turn the adjusting nut one full turn while the engine is operating. Adjustment in this mannerwill no1: allow 1:he lifters to bleed down.This would result in vanvetrain damage, probably bent push rods. For those whoprefer to adjust thE; valve lash while the engine is running, the preferred methodwould be to find the "zero lash" point as described above and then slowly turn the adjusting nut I/~ turn. Wait for the lifter to bleed down (,several engine revolutions) and again turn adjusting nut 1/4 turn. Continue this adjust-and-wait cycle until nut is one complete turn down from "zero Jash" point. Repeat sequence on remaining valves.

Engine/eng

2-5

4. Install rocker cover gasketandcover. Connectfuel line andfue~ pumpoverflow hose to carburetor. 5. Install circuit breakerbracket. Connectcrankcaseventilation hose. A 6. Startengineandcheck for oil andfuel leaks,listen for lifter noise. Checkenginetiming.

ValveSpringandSeal Repair Refer to 4.3, 5.7 EngineSection for procedure.

Cylinder HeadAssembly Thecondition of the cyminderheadand valve mechanism significantly determines the power, performance and economyof the overheadvalve engine. Extremecare should be exercised when conditioning the cylinder headand valves. Maintain correct valve stemto guideclearance,correctly grind valves andvalve seats, and properlyadjust valves. Removal 1. Remove intake and exhaustmanifold as describedunder heading Intake/ExhaustManifold. 2. Disconnect coolant hoses at thermostat housing. Disconnect spark plug wires and removespark plugs. 3. Disconnectfuel line retaining clips at thermostathousingand cylinder head. Disconnectwire harnessfrom temperaturesending unit, leaving harnessclear of clips on rocker armcover. Remove thermostat housingassemblyfrom front of cylinder head. Disconnect fuel line at the fuel pumpand remove. 4. Remove the rocker armcover. Next, loosen the rocker armnuts andpivot the rocker armsclear of the pushrods. Remove the push rods. 5. Remove the ignition coil andbracket.

860602

6. Remove the cylinder headbolts, cylinder head,andgasket. Place the cylinder headon suitable holding fixture to prevent damage to the head’s mating surface. Disassembly ~1. Removerocker arm nuts, ball seats and rocker arms. Use tool J-8062, compressthe valve springs and removevalve springs caps, springs, oil seals, springs and spring dampers.Releasethe spring compressortool and removekeys.

//~ Safety Related

2-6

E~ine/eng

’)_. Remove valves from bottom of cylinder head and place them in a rack in their proper sequenceso they can be assembledin their original positions. CJeaning [3 1. Clean all carbon from combustion chambers and valve ports using tool J-8089. Inspect the cylinder head for cracks in the exhaust ports, combustion chambers, or external cracks to the water chamber. Clean carbon deposits from head gasket mating surfaces. [3~ 2. Thoroughly clean the valve guides using tool J-8101. Clean all carbon and sludge from push rods and rocker arms. :3. Clean valve stems and heads on a buffing wheel. Inspect the valve for burned head, cracked faces or damagedstems. 4. Washall parts in cleaning solvent and dry them thoroughly. Checkfit of vanve stems in their respective bores. 4L~ 5. Measure vamve stem clearance as follows: Clamp a dial indicator on one side of the cylinder head rocker arm cover !gasket rail, locating the indicator so that movementof the valw~ stem from side to side (crosswise to the head} will cause a direct movementof the indicator stem. The indicator stem must contact the side of the valve stem just above the valve guide. With the valve head droppedabout IA6 in. off the valve seat; movethe stem of the valve from side to side using light pressure to obtain a clearance reading, if clearance exceedsspecifications it will be necessary to ream valve guides for oversize valves as outlined. [~ Excessive valve stem to bore clearance will cause lack of power, oil consumption, rough idling and noisy valves, an,d may cause valve breakage. Insufficient clearance will result in noisy and sticky functioning of the valves and disturb engine smoothness of operation. Intake and exhaust valve stem to bore clearance should be 0.001-0.0027 in. (0,025-0,007 mm). By using micrometer and a suitable hole gauge, check the diameter of the valve stem in three places; top, center and bottom. Insert hole gauge in valve guide bore, measuring at the center. Subtract highest reading of valve stem diameter from valve guide bore (’enter diameter to obtain vaJve to valve guide clearance. If clearance is not within limits use next oversize valve and ream bore to fit using suitable reamer. 6. Checkvalve spring tension with tool J-8056 spring ’tester. [N~--~ Onall models, springs should be compressedto 121hzin. at which height it should check 78-86 pounds (35,5-39,0 kg). Weak springs affect power and economy and should be replaced if below 70 pounds. (31,8 kg)

Engineleng

2-7

860005

860006

8. Checkvalve lifters for free camshaft should be smooth. If lifter should be replaced, if sponding camshaft lobe for

fit in block. Theend that contacts the this surface is worn or rough, the lifter is damaged,check the corredamage.

Repair [~] 1. Valve Guide Bore: Valves with oversize stems are available for inlet and exhaust valves in the following sizes: 0.0003 in., 0.015 in., and 0.030 in. Use the 11/32 in. diameter reamer sizes from reamer tool set J-5830-02 which are: J-4822 standard; J-5830-1, 0.003 in oversize, J-5830-2, 0.015 in. oversize and J-5830-3, 0.030 in. oversize to ream the bores for the new vamves. 2. Rocker Arm Studs Rocker arm studs that have damagedthreads may be replaced with standard studs, if the studs are loose in the head, oversize studs (available in .003 in. or .013 in. oversize) maybe installed after reaming the holes as follows: Do not attempt to install stud hole.

860007

oversize stud without reaming

Removeold stud by placing tool J-5802-01 over the stud. Install nut and flat washer, and removestud by turning nut. b. Reamhole for oversize stud. Use tool J-5715 for 0.003 in. oversize and toon J-8036 for 0.013 in. oversize. [~

C.

Coat press-fit area of stud with a hypoid axle lubricant. Install new stud using tool J-8880. Tool should bottom on head.

3. Valve Seats: Reconditioning the valve seats is very important, because the seating of the valve must be perfect for the engine to deliver the power and performance built into it. Another important factor is the cooling of the valve heads. Good contact between each valve and its seat in the head is imperative to ensure that the heat in the valve head will be properly carried away.

860008

Several different types of equipment are available for reseating valve seats; the recommendations of the manufacturer of the equipment being used should be carefully followed to attain proper results.

2-8

860009 Engme/eng

Regardless of what type of equipment is used, however, it is essential that valve guides be free from carbon or dirt to ensure proper centering of pilot in the guide. a. lnstali expanding pilot in the valve guide bore and expandpilot by tightening nut on top of pilot. b®

Place roughing stone o,r forming stone over pilot and just clean up the valve seat. Usea 46° stone for both the inlet and exhaust valve seats.

c. Removeroughing stone or forming stone from pilot, install finishing stone on pilot and cut just enoughmetal from the seat to provide a smooth finish.

860010

d. Narrow down the valve seats to the proper width for the intake and exhaust. See Engine Specifications. °This operation is done by grinding the port side with a 30 stone to lower seat and a 60° stone to raise seat. e. Removeexpanding pilot and clean cylinder head carefully to remove all chips and grindings from above operations. E5--.] ~ Valve seats should be concentric to within 0.002 in. total indicator reading. 4. Valves: Valves that are pitted can be refaced to the proper angle, ensuring correct relation between the head and stem on a valve refacing machine. Vatve stems which show excessive wear, or valves that are warped excessively should be replaced. Whena valve head which is warped excessively is refaced, a knife edge will be ground on part or all of the valve head due to the amountof metal that must be removedto completely reface. Knife edges lead to breakage, burning or pre-ignition due to heat localizing on this knife edge. if the edge of the valve headis less than %2in. thick after grinding, replace the valve. a®

ff necessary, dress the valve refacing machine grinding °wheelto makesure it is smoothand true. Set chuckat 45 mark for grinding valves.

b. Clampthe valve stem in the chuck of the machine. c. Start the grinder and move the valve head out in line with the grinder wheel by moving the lever to the left. d,

Engine/eng

Turn the feed screw until the valve head just contacts wheel. Movevalve back and forth across the wheel and regulate the feed screw to provide light valve contact.

2=9

860011

e. Continuegrinding until the valve face is true andsmooth all aroundvalve. If this makesthe valve thin the valve mustbe replaced as the valve will overheat and burn.

@

f. Remove valve from chuck and place stemin "V’" block. Feedvalve squarely against grinding wheel to grind any pit from rocker armend of stem. Only the extreme end of the valve stern is hardenedto resist wear. Donot grind end of stemexcessively. goAfter cleaning valve face andcylinder headvalve seat of

©

grinding particles, makepencil marksabout1/4 in. apart across the valve face, place the valve in cylinder head and give the valve one-half turn in eachdirection while exerting firm pressureon face of valve. h.

Remove valve andcheckface carefully, if all pencil marks have not beenremovedat the point of contact with the valve seat, it will be necessaryto repeat the refacing operation and again recheckfor proper seating. i. Grind and check remaining valves in the samemanner. 860013

Assembly 1. Starting with numberone cylinder, place the exhaust valve in the port, and place the valve spring (~ and cap ~) position. Placespring andcap on exhaustvalves. Then,using tool J-8062, compressthe spring and install the oil seal © and valve keys(~. Seethat the seal is fiat andnot twisted in the valve stem grooveand that the keys seat properly in the valve stemgroove. Place valve springs in position with the closed coil end toward the cylinder head. 2. Assemblethe remainingvalve, valve springs, spring caps, oil seals andvalve keys in the cyJinder headusing tool J-8062.Check seals by placing a vacuumcup over valve stem and cap, squeeze vacuum cup to makesure no oil leaks past oil seal.

860614

3. Checkthe installed height of the valve springs using a narrow, thin scale to measurefrom the top of the shim or spring seat in the head,to the top of the valve spring shield, if this is found in excessof 12%zin., install a valve spring seat shim, approximately 1/1s in. thick. At no time should the spring be shimmed to give an installed height of less than 1%~zinch. ff springs are to be changedwith cylinder headinstalled, refer to Valve Springand Seal Repair, in 4.3 and5.7 GLEngine Section.

2-’1 0

860015

Engine/eng

installation REAR

1. The gasket surfaces of both the head and the block must be (:lean and free of any foreign matter, and free of nicks or heavy scratches. 2. Cylinder head bolt threads in the block must be cleaned as well as the threads on the cylinder head bolts. Dirt will affect bolt torque. [3~ 3. Place a new cylinder head gasket in position over the dowel pins in the cylinder block. On engines with a steel gasket coat both sides of a new gasket with a thin, even coat of Gasket Sealing Compound.Too much sealer will hold the beads of the gasket away from the block or head. [~ The 3.0 Liter engine has a special marine head gasket. Do riot substitute an automotive head gasket. [4~ 4. Carefully guide cylinder head into place over dowel pins and gasket. Coat threads of cylinder head bolts with Perma,texor its equivalent. Install the bolts and run them downto the block. L~ 5. Tighten the cylinder head bolts, with a torque wrench, in three progressive steps following the sequenceshown. Step 1 - 35 ft. robs. (47 N-m) Step 2 - 65 ft. Ibs. (88 N-m) Step 3 - 95 ft. Ibs. (129 N.m} El. mnstalJ valve push rods downthrough openings in the cylinder head and seat them in lifter sockets. [E] 7. Install rocker arms, balls and nuts and tighten rocker arm nuts until all pushrod play is taken up. 8. InstalU thermostat housing using a new gasket. Attach coolant hoses.

8

7 FRONT 860016

9. Clean all spark plugs with abrasive-type cleaner, inspect for damage(replace if necessary) and set the gap at 0.045 in. (1,14 ram) using a wire gauge. Install the spark plugs. Tighten spark pmugsto 20 ft. Ibs. (27 N-m). 10. instal{ coil and connect both connectors to coil. Connectwire to temperature sending unit. 11. Clean manifold gasket surfaces and install new gasket over manifold studs. Position manifomdand slide it into place over the studs, making sure it seats against the gasket. Install bolts and :nuts and tighten as described under heading |ntake/Exhaust Manifold.

_zJ

860017

12. Adjust valve aash as outlined under heading Valve Lash Adjustment. install rocker arm cover and gasket. Tighten screws to 65 in. Ibs. (7,3 N-m). 13. Connectthrottle

linkage and adjust.

14. Connectfuel line and overflow hose to carburetor and install fuel line support clamps (two). Clean and install flame arrestor. 15. Start engine and check for fuel, coolant, and exhaust leaks.

Timing Gear Cover Removal 1. Drain coolant from block and exhaust manifold. Z~ 2. Securely support engine and removefront engine mount. 3. Removealternator and power steering belts. Next remove harmonic balancer and pulley assembly from pulley hub. [~ 4. install puller tool J-6978-E to pulley hub with three %-24× 2 in. bolts and removehub. Removepuller toon. 5. Removecirculating

860019

pumppulley.

6. Removecrankcase oil drain tube cap and withdraw oil with a suction pump. Disconnect oil drain tube and removeoil pan. 7. Removetiming gear cover attaching screws. Removecover and gasket. Oil Seal Replacement 1. After removingtiming gear cover, pry oil sea[ out of cover from front with a large screwdriver. 2. lnstaHI newlip seaJwith lip (openside of seal) facing inside of cover, and drive or press seal into place with tool J-23042. Oil Nozzle Replacement

860020

~] Removeold nozzle with pliers. Drive new nozzle in place using a suitable light plastic or rubber hammer.

Z~ Safety Related

2-12

860021 Engme/eng

Timing Gear Cover mnstailation 1. Clean gasket surface on block and cover. 2. Install

centering tool J-23042over end of crankshaft.

,3. Coat both sides of a newgasket with a light grease, and stick gasket in position on block. [~ 4. Pmacecover over centering tool and install cover screws. Tighten screws to 80 in. Ibs. (9 N.m) and removecentering tool. 860022

5. Install oil pan using newgaskets. Tighten I/4-20 inch screws to 80 in. Ibs. (9 N-m). Tighten ~s-18 inch screws to 165 in Ibs. (18,6 N-m). 6. Connectoil drain tube to oil pan. HarmonicBalancer Installation [5--7 EEl 1. Coat oil seal contact area on harmonic balancer with engine oil. Position hub over crankshaft and key, and start hub into position with a mallet. Using tool J-55g0, drive hub onto crankshaft until it bottoms against crankshaft gear. Crankshaft extends slightly through huband a hollow toom is necessary to drive hub completely into bottomed position. 2. Thereare two 3/s in. holes and one s/le in. hole that must be matched on hub in order to properly position timing mark. 3. Install

circulating pumppulley.

4. instalm alternator specifications.

and power steering belts and adjust to

5. Install front engine mount.

860023

6. Fill engine crankcase with proper amountof oil. 7. Lake or tank test unit and check for leaks.

\ 860024

Eng~ne/eng

2-13

Camshaft Measuring CamshaftLift Removeboth connectors from ignition

coil.

If improper valve operation is indicated, measurethe lift push rod in consecutive order and record the readings.

of each

1. Removevalve cover and rocker arms. [~ 2. Position indicator with ball socket adapter (Tool J-8520) push rod. 3. Rotate crankshaft slowly in the direction of rotation until the lifter is on the heel of the camlobe. At this point, the pushrod will be in its lowest position. 4. Set dial indicator on zero. Rotate the crankshaft slowly, or attach an auxiliary starter switch and "bump" the engine over, until the pushrod is in the fully raised position. 5. Comparethe total lift recorded from the dial indicator with specifications. The correct lift is 0.253 inch _+ 0.005 inch (8,426 + o0,127 ram). 6. Continueto rotate the crankshaft until the indicator reads zero. This will be a check on the accuracy of the original indicator reading.

860026

7. if camshaft readings for all lobes are within specifications, removedial indicator assembly. Install and adjust valve mechanism. Remova| 1. Withdraw oil from crankcase. Drain coolant from block and exhaust manifold. 2. Removevalve cover and gasket. Loosen valve rocker arm nuts and pivot rocker arms clear of push rods. 3. After noting position of rotor, removedistributor. 4. Removecoil, valvelifters.

side cover, and gasket. Removepush rods and

5. Removecrankshaft pulley and hub. Disconnect oil drain tube. Removeoil pan and timing gear cover. EE] 6. Removetwo camshaft thrust through holes in camshaft gear.

plate

screws by working

2-14

860027 Engine/eng

7. Removethe camshaft and gear assemblyby pulling it out throughthe front of the block. Support shaft carefully damagecamshaft bearings.

when removing so as not to

Inspection The camshaft has three bearings, all with the samejournal diameterof 1.8692in. to 1.8682in. (4,7478to 4,7452cm). ’These dimensionsshoumdbe checkedwith a micrometerfor an out-ofround condition. If the journals exceed0.001 in. (0,025 ram) out-of-round, the camshaftshould be replaced. The camshaft should also be checkedfor alignment. The best methodis by use of "V" blocks and a dial indicator. The dial indicator will indicate the exactamount that the camshaftis out of true. If it is out morethan 0.002 in. (0,051 mm)dial indicator reading, the camshaft should be replaced. Whenchecking, the high reading of the dial indicator indicates the high point of the shaft. Examinethe camshaft bearings and if any bearing needs replacement,replace all bearings. Gearand Thrust Plate [~ If the inspection indicated that the camshaft,gear andllhrust plate were in good condition, the camshaftend play should be checked.This clearanceshould be 0.001in. to 0.005 in. (0,025 to 0,127 mm). Disassembly ~_~if the inspectionindicated that the shaft, gearor plate should be replaced, the gear must be removedfrom the shaft. Support the camshaftgear and press shaft out of gear. E~ Thrust plate must be positioned so that woodruff key in shaft doesnot damage it whenshaft is pressedout of gear. Also, supportthe hubof the gear or the gear will be seriously damaged.

860028

Assembly 3"b assemblecamshaftgear, thrust plate andgear spacer ring to camshaft, proceedas follows: 1.. Firmly supportshaft at backof front journal in an arbor press. Place gear spacer ring and thrust plate over end of shaft, and install woodruffkey in shaft keyway. 2. Install camshaftgearandpressit onto the shaft until it bottoms against the gear spacerring. Theendclearanceof the thrust plate should be 0.001-0.005in. (0,025-0,127ram) 860029

Camshaft Bearings Removal Camshaftbearings can be replaced while the engine is disassembled for overhaul, or without complete disassembly of the engine after camshaft and flywheel have been removed. Operation is easier if crankshaft is also removed. See Crankshaft in this section. 1. With camshaft and flywheel removed, drive out expansion plug for rear cambearing by driving from inside.

860030

2. Position bearing pilot in inner bearing, install nut on puller screw far enoughso puller screw can be threaded into pilot while nut extends out front of block. 3. Install removersection onto puller screw, and then install screw through cambore and thread it into pilot. E~ 4. using two wrenches, hold screw shaft and turn puller to remove bearing.

t\

nut

EEl 5. Removepilot from shaft and install on drive handle with shoulder to handle. Drive out front and rear bearings from outside to inside

of block.

instal|ation Inner bearing should be installed bearing with screw shaft.

first

to prevent damagingend

860031

[~ Bearing O.D.’s for number one and number two are 1.999-2.001 in. (5,077-5,083 cm) and numberthree is 2.009-2.011 in. (5,103-5,108 cm). 1. Removehandle from pilot.

Install

inner bearing on pilot.

2. Position inner bearing and pilot to rear of inner bearing bore. install screw shaft (with removeradapter on it) through the block from front of engine into pilot. 3. Align oil hole on bearing with oiJ hole from oil gallery. Snug puller nut against adapter. EEl 4. using two wrenches, hold screw shaft and turn puller nut to pull bearing into place. Oil hole is on top side of bearing and cannot be seen during installation. First align bearing oil hone with oil hole in bore, and mark opposite side of bearing and block at bore to easily index oil hole during installation.

2-16

86OO32

E,0i,*Je,g

5. Attach drive bearing on pilot.

handle to pilot,

then place new number one

E2~6. Align oil hole on bearing with oil hole from oil gallery and drive bearing in from front of engine. ~4~ ~ The front bearing must be driven approximately l/e in. behind front of cylinder block to uncoveroil hole to timing gear oil nozzle. 7. Repeatstep (5) and (6) aboveto drive rear bearing into position from rear of block.

860033

Rear bearing installed position is flush with inner edge of rear cam bearing bore. 8. install

a new expansion plug at rear bearing.

Camshaftinstallation 1. if crankshaft has been removed,install it at this time. Follow procedures under the title Crankshaft in this section. If a new camshaft is to be installed, coat cam lobes with G.M. Super Engine Oil Supplement(G.M.P/N 1051858) and add rest of (:an crankcaseoil.

860034

2. install the camshaft assemblyin the engine block, being careful not to damagebearings or cam. Es~ 3. Turn crankshaft and camshaft so that the vaJve timing marks on the gear teeth will line up, then push camshaft into position. Install camshaft thrust plate to block screws and tighten them to 72-90 in. Ibs. (8-10 N-m). E6~ 4. Check camshaft and crankshaft gear runout with a dial indicator. The camshaft gear runout should not exceed 0.004 in. (0,102 mm) and the crankshaft gear runout should not exceed 0.003 in. (0,076 mm).

86OO35

5. if gear runout is excessive, the gear will have to be removed, and any burrs cleaned from the shaft or the gear replaced. E7-7 6. Check the backlash between the timing gear teeth with a narrow feeler gauge or dial indicator. The backlash should not be less than 0.004 in. (0,102 mm)nor morethan 0.006 in. (0,152 mm). 7. Install timing gear cover with newgaskets. Install new gaskets and seaner. Connect oil drain tube.

oil pan with 860036

8. InstalJ harmonicbalancer as describedunder title TimingGear (~ver in this section.

Eng~ine]eng

2-17

9. Install valve lifters and pushrods. install side cover with a new gasket and sealer. Attach coil and wires. Install distributor, positioning rotor to reference mark. 10. Pivot rocker arms over push rods. Adjust valve lash as outlined under heading Valve Lash Adjustment. 11. Add oil to engine. Unstall the alternator and power steering belts, then adjust tension. Checkand adjust timing.

Crankshaft Removaland installation 1. Removemain bearing caps and connecting rod caps and lift crankshaft out of cylinder block. Pushpistons to top of bores. 2. Inspect the crankshaft: Main bearing journals are ground to 2.2983-2.2993 in. (5,83775,8402 cm). Crankpin journans are ground to 2.099-2.100 in. (5,331-5,334 cm). These dimensions should be checked with a micrometer for out-of-round, taper or undersize, mf the journals exceed 0.001 in. (0,025 ram) out-of-round or taper, the crankshaft should replaced or reconditioned to an undersize figure that will enable the installation of undersize precision type bearings. The crankshaft should also be checkedfor runout. To perform this operation, support the crankshaft at the front and rear main bearing journals in "V" blocks, and indicate the runout of both the front center and rear center journals using a dial indicator. The runout limit of eachof these journamsis 0.002 in. (0,051 mm).if the runout exceeds 0.002 in. (0,051 mm), the crankshaft must repaired or replaced. 3. Removerear main bearing oil seal. 4. Removeold bearings from cylinder block and caps. install bearings in the cylinder block and caps.

new

Main bearings with oil holes are the upper halves of the bearings and are inserted between the crankshaft and cylinder block. 5. Oil crankshaft journals and carefully place the crankshaft in the bearings.

6. install all bearing caps and bolts. Tighten all main bearing cap bolts, except the rear mainbearing, to 60-70 ft. Ibs. (81-95 N-m}. VVhentightening rear main bearing cap, tighten bolts to 10-12 ft. Ibs. (14-16 N-m) first, then tap end of crankshaft rearward ,with lead hammer(this wilm locate bearing cap and bearing). Then tap crankshaft forward (this will line up both upper and lower crankshaft bearing thrust surfaces). Proceedwith final tighl:ening of rear main bearing cap bolts to 60-70 ft. Ibs. (81-95 N.m)= 7. Checkmain bearing clearance and crankshaft end play. Install new rear bearing oil seat. Instatl connecting rod bearings and caps.

Connecting Rod Bearings Connecting rod bearings are available in standard sizes and undersizes of 0.001 in., 0.002 in., 0.010 in. and 0.020 in. (,0,025, 0,051, 0,254, 0,508 mm). These bearings are not shimmed and when clearances become excessive the next undersize bearing should be used. Do not file rod or rod caps. Removaland Inspection 1. Withdraw oil,

disconnect oil drain tube and removeoil pan.

2. Removethe connecting rod bearing cap. Wipe bearing and crankpin clean of oil. L~ 3. Place a piece of Plastigage gauging plastic the full width of the bearing on crankpin (parallel to the crankshaft).

860037

4. Reinstall the bearing cap and evenly tighten the retaining nuts to 35 ft. Ibs. (47 N-m). E~ Do not turn crankshaft with the gauging plastic

installed.

E~ 5. Remove the bearing cap and, without removing the gauging plastic, check its width at the widest point with the Ptastigage scale. if the crankpin is out-of-round be sure to fit the beariing to the maximum diameter of the crankpin. If the flattened plastic is not uniform from end to end in its width, the crankpin or bearing is tapered, has a low spot or someother irreguiarityg Check the crankpin with a micrometer for taper if the flattened gauging plastic indicates morethan 0.001 in. (0,025 mm)difference.

860038

6. If the reading is not over 0.0009in. (0,0229 ram} or not less than 0.0014 in. (0,0356 mm)the fit is satisfactory. If however, the clearances are not within these limits, replace the bearing with the proper undersize bearing. The bearings are not adjustable and no attempt should be madeto adjust by filing or shimmingthe bearing caps. installation Newbearing clearance should be 0.00085-0.00135 in. (0,021590,03429 mm). 1. Rotate the crankshaft after bearing adjustment to be sure the bearings are not too tight. 2. Check connecting rod end clearance between connecting rod cap and side of crankpin. See Engine Specifications for clearance. 3. Install oil pan with new gaskets and seals. Connect oil drain tube. Refill with engine oil.

CrankshaftBearings

860039

The main bearings are of the precision insert type and do not utilize shims for adjustment, if the clearances are found to be excessive, a new standard or oversize bearing, both upper and mowerhalves, will be required. If, for any reason, main bearing caps are replaced, shimming may be necessary. Laminated shims for each cap are available for service. Shim requirements will be determined by bearing clearance. The clearance may be checked by using Plastigage gauging plastic. Whenone bearing is being checked, all the other main bearing caps must be in place and tightened to specifications. The main bearings used as service replacement are of high quality with close tolerances of fit and will not require line reaming on installations. The close dimensional tolerances ensure an equalized bearing surface at all points on the crankshaft when replaced in sets. Main bearings crankshaft.

may be replaced without

removing the

1. Withdraw oil from crankcase. Disconnect oil drain tube. Removethe oil pan.

2. Removethe spark plugs. 3. Remove cap on main bearing requiring replacement and remove bearing from cap. Install a main bearing removing and installing tool in the oil hole in the crankshaft. Use tool J-6098-01. if such a tool is not available, a cotter pin maybe bent as required to do the job. 4. Rotate the crankshaft clockwise as viewed from the front of the engine. This will roll upper bearing out of engine. 5. Oil new upper bearing and insert plain (unnotched) end of the bearing between crankshaft and indented or notched side. Rotate the bearing into place. 6. Install new bearing in bearing cap. ]’he rear main bearing journal has no oil hole drilling. To removethe upper bearing half proceed as follows after cap is removed: a. Use a small drift punch and hammerto start the bearing rotating out of block. Use a pair" of pliers to hold the bearing thrust surface to the oil slinger, and rotate the crankshaft to pull bearing out. C°

To install, start the bearing (side not notched]~ into notched side of block by hand, then use pliers as before to turn bearing half into place. The last I/4 in. movementmaybe done by holding just the slinger with pliers (taped jaws) or tap in place with a drift punch.

7. Check bearing clearance per paragraph below. Main Bearing Clearance Plastigage gaugingplastic is a wax-like plastic material which will compress evenly between the bearing and journal surfaces without damaging either surface. To obtain the most accurate results with gauging plastic, certain precautions should be observed. If the engine is upside down, the crankshaft will rest on the upper bearings and it can be assumedthat the total clearance can be measured between the cap bearing and journal. ~ot~ To ensure the proper seating of the crankshaft, the rear main bearing oil seamshould be removedand all bearing cap bolts should be at their specified torque, in addition, preparatory to checking fit of bearings, the surface of the crankshaft journa,I and bearing should be wiped clean of oil. 1. Starting with the rear main bearing, removebearing cap. Wipe oil from journal gauging plastic.

Engine/eng

and bearing cap before applying

2-21

EEl 2. Place a piece of gauging plastic the full bearing (parallel to the crankshaft) on the journal.

width of the

I~ Do not rotate the crankshaft while the gauging plastic between the bearing and journal.

is

3. Install the bearing cap and even{y tighten the retaining bolts to 60-70 ft. Ibs. (81-95 N.m). 4. Removebearing cap. The flattened gauging plastic will be found adhering to either the bearing or journal. On the edge of gauging plastic packing envelope there is a graduated scale measuring in thousandths of an inch.

860041

5. Without removing the gauging plastic, check its compressed width (at the widest point) with the graduations on the gauging plastic envelope. Normally, main bearing journals wear evenly and are not out-of-round. However,if a bearing is being fitted to an out-ofround journal be sure to fit to the maximumdiameter of the journal. Jf the bearing is fitted to the minimumdiameter of the journal, and the journal is out-of-round 0.001 in. (0,025 ram) more, interference betweenthe bearing and journal will result in rapid bearing failure. If the flattened gauging plastic tapers toward the middle or ends, there is a difference in clearance indicating a taper, low spot, or other irregularity of the bearing or journal. Be sure to check the journal with a micrometer if the flattened gauging plastic indicates more than 0.001 in. (0,025 ram) difference. 8. ff the bearing cJearance is not over 0.0035 in. (0,0889 ram) {worn) or 0.003 in. (0,076 ram) (new), or less than 0.001 in. (0,025 ram), the bearing is satisfactory, if the clearance is not within these limits replace the bearing.

860042

[~ If a new bearing cap is being installed and clearance is less than 0.001 in. (0,025 ram), check for burrs or nicks; if none are found then install shims as required. 7. A 0.002 in. (0,051 mm) undersize bearing may produce the proper clearance. If not, it will be necessary to regrind the crankshaft journal for use with the next undersize bearing. [~E] Bearings are available in standard sizes and various undersizes. See your parts catalog. 8. Oil newbearings with engine oil prior to installing end caps. Proceed to the next bearing. After all bearings have been checked, rotate the crankshaft to see that there is no excessive drag.

2-22

Engine/eng

3r~ 9. Checkthe end play by forcing the crankshaft to its extreme front position. Checkat the front side of the rear main bearing with a feeler gauge. This clearance should be from 0.002-0.006 in. (0,051-0,152 mm). 10. install a newrear main bearing oil seal in the cylinder block and main bearing oil cap as described below.

Rear Main Bearing Oil Seal Replacement r~o~ Care shouUd be taken when removing the rear crankshaft oiE seal so as not to nick the crankshaft sealing surface. [4~ 1.insert a screwdriver into the notches provided in the seal retainer and pry the seal out. Take care not to damagethe crankshaft sealing surface. 860043

2. inspect chamfer on crankshaft for grit, loose rust, and burrs. (,’lean seal running surface on the crankshaft with a non-abrasive cleaner. EEl 3. Lubricate the inner and outer diameter of new seal with engine oil. Install the seal on J-35621. Position J-35621 against the crankshaft. Thread the attaching screws into the tapped holes in the crankshaft. 4. Tighten screws securely. This will ensure the seal is ins;tailed squaremyover the crankshaft. Turn handle until it bottoms then remove J-35621.

Oil Seal Retainer Replacement 1. RemoveFlywheel and oil pan. Removescrews, nuts and seaJ retainer. Removegasket. 2. Removerear crankcase oil seal as previously stated and clean gasket surfaces on block and seal retainer. [No-"~

VVhenever

seal

retainer

is

removed,

a new retainer

DR1878

gasket

and rear crankshaft oil seal must be installed. 3,. Attach gasket to block. No sealer is required. Install seal retainer, screws and nuts. Tighten to 135 in. Ibs. {15,3 N-m). 4. lnstaml oil pan. install rear crankshaft oil seal as outlined previousny,install fl’y,wheel.

Piston and Connecting Rod

DR1879

Piston and Rod Remova| 1. Withdraw crankcase oil Disconnect oil drain tube. Removeoil pan. 2. Drain coolant from block and exhaust manifold, then remove cylinder head.

Er,~ine/~nQ

2-23

3. Removeany ridge and/or deposits from the upper end of the cylinder bores with a ridge reamer. Movepiston to the bottom of its travel and place a cloth on top of piston to collect the cuttings. After ridge and/or deposits are removed,turn crankshaft until piston is at the top of its stroke and carefully removecloth with the cuttings. 4. Checkconnecting rods and pistons for cylinder numberidentification and if necessary, mark them. 5. Removeconnecting rod cap nuts and caps. Push the rods away from the crankshaft and install caps and nuts moosely to their respective rods. 6. Push piston and rod assemblies away from crankshaft and out of the cylinders. It will be necessary to turn the crankshaft slightly to disconnect someof the rods and push them out of the cylinder. Piston and Rod Disassembly 1. Install pilot of piston pin removingand instalming tool J-24086 on piston pin. 2. install piston and connecting rod assembly on support and place assemblyin an arbor press. Press pin out of connecting rod. 3. Removeassembly from press. Removepiston pin from support and remove tool from piston and rod. 4. Piston pins are a matchedfit to the piston and not available separately. Piston pins will not becomeloose enoughto cause a knock or tapping until after prolonged use. in such cases a new piston and pin assembly should be installed. Piston pins should be capable of supporting their own weight in either pin boss whencoated with light engine oil at 60° F. Higher or lower temperatures wilm cause false indications. Pistons and pins are serviced as assemblies. Checkfit of used piston pins. Use a dial bore gaugeor telescoping snap gauge for the bore, and a micrometer for the pin. Wearlimit on piston pin is production clearance plus 0.001 in. (0,025 mm). Replace piston and pin assembly if wear is excessive.

860046

CJeaning and Inspection Clean varnish from piston skirts and pins with a cleaning solvent. DO NOTWiREBRUSHTHE PISTONSKIRT. Clean the ring grooves with a groove cleaner, and makesure oil ring holes and slots are clean.

2-24

Englne/eng

Inspect the piston for cracked ring lands, skirts or pin bosses, wavy worn ring lands, scuffed or damagedskirts, or eroded areas at top of the piston. Replace pistons that are damaged or otherwise show signs of excessive wear. Piston and Rod Assembly 1. Lubricate piston pin holes in piston and connecting ~rod to facilitate installation of pin. :2. Position connectingrod in its respective piston so that flange or heavy side of rod at the bearing end will be towards front of piston (cast depression in top of piston head). [2~ 3. install piston pin (~) on installer pilot (~ in support(~). 4. Install and rod.

® and pilot spring ~)

piston and rod on support, indexing pilot through piston

5. Place support on arbor press, start pin into piston and press on installer until pin pilot bottoms. 6. Remove installer and support assembly from piston and connecting rod assembly. Check piston pin for freedom of movement in piston bore.

Piston Rings Piston rings are furnished in standard sizes as well as several oversizes. See your parts catalog. Oit control rings used on all engines consist of two segments (rails) and a spacer. Compressionrings in all engines are the deep section twist type, 0.0775-0.0780 in. (1,969-1,981 ram) wide. This type installed maintains diameter section.

compression ring takes its name, twist type, from its position which is cocked or twisted. It assumesand this position for life because the upper edge of its is chamfered, making the ring unbalanced in cross

[~ All compression rings are marked with the letter "GM" cast in the upper side of the ring. Wheninstalling compression rings, makesure the side marked"GM" is toward the top of the piston. Removal I. Removepiston rings by expanding them and sliding them off the ends of the piston. Tool No. J-8037 is available for this purpose.

E..i~/..~

2-25

2. Checkpiston ring grooves by carefully removingall particles of carbon. Also check for burrs or nicks that might cause rings to hang up. installation 1. Select rings comparablein size to the piston being used. It is important that each ring be fitted to its individual cylinder for proper gap spacing and to its individual piston and groove for proper clearance. 2. Slip the ring in the cylinder bore; then, using the head of a piston, press the ring down into the cylinder bore about two inches. Using a piston in this way will place the ring square with the cylinder wails. r=~ 3. Checkthe space or gap betweenthe ends of the ring with a feeler gauge. 4. ff the gap betweenthe ends of the ring is beJowspecifications, removethe ring and try another for fit.

860048

5. Fit eachring separately to the cylinder in whichit is going to be used. 6. New pistons, rings and cylinder bores wear considerabmy during seating and gaps widen quickly; however, engine operation will not becomeseriously affected if ring gaps do not become greaterthat 1,~2in. [~ 7. Slip the outer surface of the compression ring into the piston ring groove. Roll the ring entireay around the groove to makesure that the ring is free and does not bind in the groove at any point. If binding occurs, the cause should be determined and removedby carefully dressing with a fine cut file. However,if the binding is causedby a distorted ring, install a newring.

880049

8. Install the oil ring spacerin the oil ring groove and position gap in line with piston hoJe. HoJdspacer ends butted and install steen rail on top side of spacer. Position gap at least one inch to left of spacer gap, then instal[ second rail on lower side of spacer. Position gap at least one inch to right of spacer gap. 9. Flex the oil ring assemblyin its groove to makesure ring is free and doesnot bind in the groove at any point, if binding occurs, the cause should be determined and removed by carefully dressing with a fine cut fine. However, if the binding is caused by a distorted ring, install a newring.

860050

[3~ 10. Proper clearance of the piston ring in its piston ring groove is very important in maintaining engine performance and in preventing excessive oil consumption. Therefore, whenfitting newrings, the clearances betweenthe top and bottom surfaces of the ring grooves should be inspected. [3~ 11. The compression rings should be fitted clearance is 0.0020-0.0035 in. (0,051-0,089 mm).

so that the

12. Assemblethe rings to the pistons as they are fitted and makea final test of the ring fit in the grooves by repeating the fitting procedure given above. Expander ends must not align with the ring gap. Piston and RodInstallation 1. Lightly coat pistons, rings and cylinder walls with light engine oil. [~ 2. With bearing caps removed, install bearing cap bolts.

tool

J=6305-01 on

L~ I~ 3. install each piston in its respective bore, using tool J-8037 on each assembly. The side of the piston with the cast depressionin the head should be to the front of the cylinder block and the oil hole on connecting rod toward the camshaft side of the engine. Guide the connecting rod bearing into place on the crankshaft journals with the long detail of tool J-6305-01. Use J-8037 to compresspiston rings. 4. Oil bearings and install bearing caps. Install cap retaining screws and nuts. "Tighten nuts to 35 ft. Ibs. (47 N-m). Checkthe bearing clearance as described previously. 5;. install oil pan gaskets, seals and oil pan. See Oil Pan. Connect oil drain tube. 6. Instalt cylinder lnstaiJation.

880051

V

head gasket and head. See CyKinder Head

7. Refill crankcase and check for leaks. Test unit and check for coolant leaks.

Cylinder Block inspection 1. Checkthe cylinder block for cracks in the cylinder walls, water jacket and main bearing webs.

860052

E,,~i.o/~o~

2-27

EEl 2. Checkthe cylinder walls for taper, out-of-round or excessive ridge at top of ring travel. This should be done with a dial indicator (use TooJ J-8087). Set the gauge so that the thrust pin must be forced in about 1/4 in. to enter gauge in cylinder bore. Center gauge in cylinder and turn dial to "0". Carefully work gauge up and down cylinder to determine taper and turn it to different points around cylinder wall to determine the out-ofround condition, if cylinders were found to have more than 0.002 in. (0,051 ram) out-of-round, boring will be necessary. Repair The performance of the following operations is contingent upon engine condition at time of repair. if the cylinder block inspection indicated that the block was suitable for continued use except for out-of-round or tapered cylinders, they can be conditioned by honing, or boring and honing. If the cylinders were found to have messthan 0.005 in. (0,127 ram) taper or wear, they can be conditioned with a hone and fitted with 0.001 in. (0,025 ram) oversize pistons. A cylinder bore of less than 0.005 in. (0,127 mm)wear or taper maynot entirely clean up when fitted to a 0.001 in. (0,025 ram) oversize piston, if it is desired entirely clean up the bore in these cases, it will be necessaryto rebore for an oversize piston, if morethan 0.005 in. taper or wear exists, they should be bored and honed to the smallest oversize that will permit complete resurfacing of all cylinders.

860{)53

Piston Selection Replacementpistons are available in two sizes, see the appropriate parts catalog for part numbers.The size identification of the piston is markedin ink on the piston top. To determine the correct size of piston needed, measure the cylinder bore with a telescope gauge and micrometer, and subtract the base cylinder bore diameter, 4.000 in. (10,180 cm) from the measureddiameter. Next locate this dimension on the Piston Selection Chart. The numbershownon the chart in the box above the dimension is the marking on the piston which should be used.

2-28

Er~|ne/eng

ExampJe"A’: Cylinder Bore Measurement Base Cylinder Bore Diameter

4.002 in. (10,165 cm} (Worn Bore)

Difference

0.002 in. (0,051 ram)

4.000 in. (10,160 cm}

The number in the box above 0.002 (0,051 mm)in is $7. Therefore, in this case a 0.001 in. (0,025 mm)oversize piston marked ,would be used. ExampBe"B": Cylinder Bore Measurement Base Cylinder Bore Diameter

4.032 iin.

Difference

0.032 iin. (0,813 mm)

(10,241 cm) (Bored Out Bore)

4.000 iin. (10,160 cm)

"The numberin the box above 0.032 in. (0,813 mm)is 4. In this e×ampfe, a 0.030 in. (0,762 ram) oversize piston marked4 would be used.

SERVICE PISTON MARKING

DR4649

Boring 1. Before using any type boring bar, the top of the cylinder" block should be dressed to remove any dirt or burrs. This i,.~ very important. Otherwise, the boring bar maybe tilted which would result in the rebored cylinder wall not being at right angles to the crankshaft. 2. The piston to be fitted should be checked with a micrometer, measuringjust below the lower ring groove and at right angles to the piston pin. The cylinder should be bored to the samediameter as the piston and honed to give a clearance of 0.0025-0.0035 in. (0,064-0,089 ram). 3. The instructions furnished by the manufacturer of the equiprnent being used should be carefully followed. E~i~

2-29

Honingand Piston Fit 1. Whenthe cylinders are to be honed only for use of a standard piston or for final finishing after they havebeenrebored to within 0.002 in. (0,051 ram) of the desired size, they should be finished with a hone. Roughstones maybe used at first and fine stones for the final operation. 2. Place the hone into a cylinder bore and expandthe stones until the hone can just be turned by hand. Connecta 1~ in. (0,217 ram) electric drill to the hone and drive hone at drill speed while moving hone up and down entire length of cylinder until hone begins to run free. During this operation a liberaJ amount of kerosene should be used as a cutting fluid to keep the stones of the hone clean. Move hone slowly up and down with rough stones, but movehone up and down rapidly enoughwith the fine stones to producea final bore finish of very fine surface scratches in a cross-hatch pattern of approximately 45° to 60°. The marks should be clean but not sharp, and free from embeddedparticles or torn or folded metal. 3. Expand the stones against the cylinder bore and repeat the honing operation until the desired bore diameter is obtained. 4. Occasionally during the honing operation, the cylinder bore should be thoroughly cleaned and the piston selected for the individual cylinder checkedfor correct fit. 5. Checkfit

of the aluminumpistons in the following manner:

Thoroughly cleat’1 cylinder bores with soap and hot water to removeall grit particJes. ao

Measure the cylinder bore diameter with a tenescope gauge and micrometer 21~ inches (6,35 cm) from top cylinder bore at 90° from crankshaft axis.

b. Next measurethe diameter of the piston skirt just below the lower ring groove and at right angles to the piston pin. c. if the difference is greater than the maximum allowable (see Boring, step 2), try another piston or lightly honethe cylinder bore to obtain the proper fit. d,

Should the difference be less than the minimumallowable {see Boring, step 2), try another piston. If proper fit cannot be obtained, it will be necessary to rebore the cylinder to the next oversize piston.

e. Mark each piston after fitting to correspond with the cylinder to which it has been fitted. Proceed to hone cylinders and fit the remaining pistons.

2-30

Engino/erlg

Handlethe pistons with care and do not attempt to force ,them through the cylinder until the cylinder has beenboredto correct size. This type piston can be distorted throughc~mreless handling. 6. Thoroughlyclean the cylinder bores with hot water and soap. ’.Scrub well with a stiff bristle brushandrinse thoroughlywith hot water, it is extremelyessential that a goodcleaningoperation be performed.If any of the abrasivematerial is allowedto remainin the cylinder bores, it will rapidly wearthe newrings andcylinder bores, in addition, the bearingwill be lubricated by the contaminated oil The bores should be swabbed several times with light engineoil anda clean cloth andthen wipedwith a clean dry cloth. Cylinder should not be cleanedwith keroseneor gasoline. Clean the remainderof the cylinder block to removethe excessmaterial spreadduring the honing operation.

866054

Distributor LowerBearing "[’he distributor lowerbearingis a bronzebushingpressedinto the lower side of the engineblock. Its upperinside diameterpilots the distributor shaft, and the outside diameterextending below the block pilots the oil pump. ’.Some engines have a thrust washer at the upper end of the bushing bore. Thethrust washer,whereused, maybe replaced at the sametime the bushing is replaced. Thelower bushingwill ordinarily require only a clearanceor wear check during engine overhaul. Whendistributor shaft-to-bushing clearanceexceeds0.0035in. (0,0889 ram) the bushing should replaced as follows with oil pumpand distributor removed: [1=~ 1. Install tool J-9534-01into bushing and using ~= slide hammer,remove the bushing.

86O055

Protect your eyesfromfragments.Wearsafety glasseswhen striking these tools, handles,drivers, etc. Tool endmaymush=room after being repeatedly struck. Always grind off any re|led ~ges before using tool. Use soft face hammerswhenever possible. 13 2. Usinga drift up through bushingbore, drive thrust washer (if installed) out of bore andremovefrom block. :3. Clean bushingbore in block and checkfor burrs or damage. 13 4. if thrust washer was removed, start new washer in position in bore anddrive into place using tool J-9534-01. !5. Usingtool J-9535with driver-bolt in driver handle,install driver into newbushingfrom large inside diameter.

860056

L.LJ 6. Placebushingand driver on block anddrive the bushingin position. Depth is determined by tool bottoming against the block. 7. Remove tool from bushing. It is possible that the bushingwith minimum I.D. will collapseenough,during installation, to slightly seize the installer arbor, mf this happens,removeinstaller tool using slide hammer in driver bolt hole of driver handle. This will not damage the bushingand the tool is designed for this purpose,shouldit occur.

Circulating Pump Removal 1. Openpetcocks on port side and drain coolant from block and exhaust manifold. Disconnectwater hose from circulating pump. 2. Loosenfour screwsholding circulating pumppulley to circulating pump. 3. Loosenalternator bracket bolts and removealternator belt. Removecirculating pumppulley and bolts° Unscrewbolts and removethe circulating pumpfrom the engine. Pull the pumpstraight out of the block first, damageto impeller.

860057

to avoid

inspection if the seal is leaking replace the pump.if the bearingis roughor allows excessive sideways movement of the shaft, replace the pump.If the impeller has excessiveerosion replace the pump= |nstaflation This pumphas a special shaft and bearing assemblyand a special seal assemblyintendedfor marineservice. Donot substitute with an automotive pump. 1. Apply Gasket Sealing Compoundto a new pumpto block gasket. Install pumpassemblyon cylinder block and tighten bolts securely. 2. Install circulating pumppunley. Attach alternator belt and adjust. Refer to Genera||nformationsection for specifications. 3. Connectcoolant hosesto circulating pump.Lakeor tank test unit andcheckfor leaks.

OiR Pan Replacement Removal 1. Remove oil using a suction pump.

2-32

Engine/eng

2. Removeoil ,gasket.

withdrawal

tube. Removescrews, oil

pan and

ilnstallation 1. Thoroughlyclean all gasket sealing surfaces. Apply R’rv sealer ¯ to the front andrear of the block. 2. Install gasket on the block. Install oil pan. Tighten 1/4×20screws to 80 in. Ibs. (9 N-m) and ~ex18screws to 165 in. ibs. (18,6 N-m). dlnstall oil drain tube and fill crankcasewith engine oil.

OU Pump Replacement 12~ The oil pumpconsists of two gears (~) and a pressure relief ’valve (~) enclosed in a two-piece housing ©. The pumpis driven #ore the distributor driveshaft which in turn is driven by a helix gear on the camshaft. "The oil pumpis flange mountedto the cylinder block with two bolts, and piloted on the outside of the lower distributor bronze bearing. Oil pressure passes through an opening in the mounting "Flange to the cylinder block, then into the full flow oil filter. The pumpcover is equipped with the pressure regulator valve that =regulates oil pressure at approximately 40-60 PSI (135,1-202,6 kPa) at 2000 RPMThe pumpintake is of the fixed screen type. =meshscreen (~ filters out small particles of dirt and sludge which may be present. A baffle incorporated on the intake screen has been designed to eliminate pressure loss due to suddensurging stops, turns, and acceleration. IIn the event that a screen becomes plugged a steel grommet opens and bypasses oil to the pump. Removal and Disassembly 1. Withdraw oil. Disconnect oil withdrawal tube. Removescrews, oil pan and gasket. Removeoil withdrawal tube fitting from oil pan. 2. Remove oil pickup tube clamp bolt. Remove two flange mounting bolts. Removepump and screen as an assembly. :3. Remove four cover attaching screws, cover, gasket, idler gear, and drive gear and shaft. ,4. Removepressure regulator valve and valve parts. If necessary, remove oil pump suction pipe and screen by pulling from pump Inousing.

Engine/eng

2-33

860058

Do not disturb oil pickup pipe on screen. This pipe is located at assembly. 5. Washall parts in cleaning solvent and dry using compressed air. inspection Shouldany of the following conditions be found during inspection operations, the defective parts should be replaced. 1. inspect pumpbodyfor cracks and excessivewear. inspect oil pumpgears for excessive wear or damage. 2. Checkshaft for loosenessin the housing.Checkinside of cover for wearthat wouldpermit oil to leak past the endsof gears. 3. Checkthe oil pick-up screen for damage to screen or relief grommet. 4. Checkpressureregulator valve plungerfor fit in cover. Assemblyand installation 1. Placedrive gear andshaft in pumpbody. Install idler gear so that smoothside of gear will be towardthe cover. 2. install a newpumpto cover gasket to ensure correct end clearanceof the gears. 3. Install suction pipe and screen assemblyto pumpbody and install coverandattachingscrews.Tightenscrewsto 65-75in. Ibs. (7-8 N-m)andcheckto see that shaft turns freely. 4. Install regulator valve plunger, spring, retainer andpin. 5. Align oil pumpdriveshaft slot to matchwith distributor tang. Install oil pumpto block, positioning flange over distributor lower bushing. Useno gasket. Oil pumpshouldslide easily into place. If not, removeand relocate slot or determineother problem. 6. Attach and tighten oim pickup tube clamp. 7. Install oil panusing newgasketsand seals. [~] 8. Install withdrawaltube fitting to pan; leave screwloose. Orient fitting and attach withdrawal tube. Then tighten both fitting screwandflare nut to 15-18ft. Ibs. (20-24N-m}. 9. Fill crankcase with oil.

31576

Oil Filter BypassValve Inspection Removethe oil filter and check the spring and fiber valve for operation. Checkfor a cracked or broken valve. Replacement If replacement is necessary: 1. Removethe valve by prying it out with a screwdriver.

2888

2. Install a newvalve and seat it by tapping into place using a 9Ae in. thin wall deep socket and hammer. 3. Install oil filter

accordingto manufacturer’sinstructions.

Front Engine Mount Removal [2~ 1. Removetwo lag screws and washers from mounts;. 34732

~/~ 2. Uft engine with hoist capable of lifting at least 1000 lb. (454 kg) minimum capacity hoist to allow removalof front mount and bracket. [3-~ 3. Removefour mount screws and lock washers. Remove front engine mount and spacer (port side) from engine. Disassembly [~ ~ Prior to disassembly of front mount assembly, measure distance between large washer on bracket and small washer on lower mount and record for reference during reassernbly. [5-~ [~ 1. Put wrench on flat of trim adjustment shaft socket on top nut, and remove engine bracket and spacer.

18367

and

22657

16383

0

o

@

m

22656

16351

22654

[~ 2. Removetwo bolts from engine bracket and removerubber mount assembly. [-~ 3. Removelower nut and washeron shaft and removeshaft from lower mount. [~ 4. Uponcomplete disassembly, check pieces and replace where necessary. Reassemb|y Z~ 1. Place one nut and washeron trim shaft, then set trim adjustment

shaft

in lower mount, |nstaRI

remaining

washer, and

screwon lower nut. Makesureat least three shaft threadsextend through nut. Tightennuts finger tight, do not tighten at this time. [~ 2. Place engine bracket spacer on shaft. [~] 3. Attach rubber mountto engine bracket with two bolts and tighten to 30-35ft. Jbs. (41-47N.m). [~ 4. Place engine bracket assemblyon shaft with large and small washerand tighten nut to 50-60ft. lbs. (68-81N-m). 22653

Installation [~ 1. Attach engine bracket and port side spacer to the engine with two long bolts and lock washers(port side) and two short bolts and lock washers(starboard side). Tighten long port side bolts to 48-56ft. Ibs. (65-76N.m)andstarboardbolts to 32-40ft. Ibs. (43-54N-m). [~] ~ 2. To reset engine height to original position, refer to measurement points and dimensionrecorded in Step 4 of Removal. Loosennuts to adjust shaft and mountposition to desired height. Hold one nut and tighten the other to 115-140ft. Ibs. (156-190N.m).

Safety Releted

2-36

16382

34731 Engme/eng

Z~ 3. Install lag screwsend tighten securely.

Front Mount Height Adjustment ,/~k 1. Support engine with a hoist capable of lifting rib. (454kg). [~ 2. Removeboth lag screws from lower front

at least 1000 mount.

[~ Z~ 3. Loosen nuts securing lower mount to trim shaft. Reposition lower mount to desired position, then retighte, lower mountnuts to 115-140 ft. Ibs. (156-190 N-m). 11-~ ~ 4. install securely.

16367

two lag screws in lower mount and tighten

High-Rise Exhaust Elbow Replacement Removal 1. Loosen all four hose clamps. Lubricate exhaust pipe with a soapy water solution, and slide hose down off exhaust elbow. :2. Loosenhose clamp and disconnect cooling hose from inside of exhaust elbow. Then remove hose fitting.

2972

3. Removethe two screws ~) and swing anchor bracket out of the way. Then remove the two nuts and lock washers ~. [1~ 4. Loosenthe elbow with a soft hammer,then lift manifold. Removeand discard the elbow gasket.

it off the

Installation 1. Thoroughly clean the manifold and elbow gasket sulrfaces. Apply Gasket Sealing Compoundto both sides of a new gasket, ,and place it on the manifold.

2888

34729

Engineleng

~ Safety Related

2-37

2284~

[~ 2. Mount the elbow on the manifold. Install the throttle anchor bracket, and secure with the two screws (~ and the two nuts and lock washers(~).Tighten all four to 12-14 ft. Ibs. (18-19 N.m). Slide the exhaust hose all the way onto the elbow. 3. Install hose.

hose fitting

on the inside of elbow and connect cooling

~] 4. Position the upper clamps in the top two channels and tighten them securely, install and securely tighten the two lower clamps. 34728

5. Reconnectthrottle cable to carburetor and throttle plate. Securewith cotter pin.

linkage

Exhaust HoseReplacement Removal 1. Remove high rise exhaust elbow following High-Rise Exhaust Elbow Replacement.

procedure

[~] 2. Removeclamps and slide hose off exhaust pipe. 34727

installation [~] ~ One end of exhaust hose has two ribs © around the circumference. Position this end up when installing hose to ensure secure attachment. 1. Place two No. 64 hose clamps over exhaust pipe if they were removed. r~ 2. Lubricate inside diameter of hose with a soapy water solution to ease installation, and slide hose all the way onto exhaust pipe. Place two No. 64 clamps around top section of hose.

22647

3. Complete hose and high-rise elbow installation following procedure in High-Rise Exhaust Elbow Replacement.

16350

i

//~ Safety Related

2-38

Engme/eng

Exhaust (Flapper) Valve Replacement Removal 1. The exhaust valve is at the upper end of the exhaust pipe. Removeexhaust elbow and exhaust hose. 2. Usinga small drift or punch@,pushthe exhaustvalve pin out of the exhaustpipe. ~=~ [~ 3. Removepin and valve. Push out two rubber bush= ings.

6373

installation 8~ 1. Apply Scotch Grip Rubber Adhesive to two new rubber bushingsand push into exhaust pipe. [~ 2. Lightly lubricate exhaustvalve pin with oil. Position valve in exhaust pipe with long side of valve down. Pushpin through bushingand exhaustvalve until flush with both sides of pipe. Checkexhaust valve for freedomof movement. If the valve is not positionedproperly (long lip down), will restrict exhaustflow andfail to preventwater frombackingup into exhaust system. Boat performancecould be adversely affected, and major powerheaddamagecould occur.

6375A

3. install exhausthoseand elbow.

6376

6377

1

20034

6675

6675

Engine Coupler Replacement Removal 1. Removeengine from boat following instructions Removal andInstallation section.

in Engine

if coupler is beingreplaceddueto coL~pierfailure (rubber hub of spiined hub), checkengine alignmentafter installing new coupler. See EngineAlignmentin EngineRemova| and Instal|ation section.

6710

2. Cut tie strap holding flywheel housing drain hose to starter motor. [~ [~ 3. Take out screws holding flywheel housing cover (~), then slide out cover. [~ 4. Unscrewouter nut on ground stud, and take off lock washerand electrical leads. Remove inner nut, lock washerand washer. Removesimilar ground stud hardwareon opposite side of block. 5. Removescrews and washersholding shift bracket, and move bracket aside.

6712

6. Unscrewremaining flywheel housing bolts, lock washersand washers. Note position of clamps so they can be installed in original position. [~ 7. Lift flywheel housingoff engineblock and set aside. [~ 8. Unscrewsix nuts and lock washers,then pulm coupler off flywheel. 6714

2-40

Eng~ne/eng

installation L~ 1. Slide coupler onto crankshaft studs, install lock washers and nuts. Use a crowfoot wrenchand tighten nuts to 40-45t"t. Ibs. (54-61 N.m). ET~ 2. Install flywheel housing, Place clamps in their original positions, and attach shift bracket. Tightenscrewsto 28-36t"t. Ibs. 138-49 N.m). Z~ 3. Place washer, lock washer and nut on ground stud. Tighten inner nut to 35-40 ft. ibs. (47-54 N-m). Attach electrical leads ground stud. install lock washerand tighten outer nut securely. install ground stud hardware on opposite side of block. ~8~ 4. Slide flywheel cover up into place, install tighten them to 60-84 in. Ibs. (7-9 N.m).

6711A

screws and

Eg~ 5. Attach flywheel housing drain hose ~) to starter with tie strap.

motor

6. Install engine in boat following instructions in Engine Removal and installation section. 20034

14704

Engine Specifications 1. GeneralSpecifications Type - No. of Cylinder ..................... Bore and Stroke .......................... Piston Displacement ....................... Cylinder No. {front to rear) .................. Firing Order ............................. Compression Ratio ........................ Thermostat Opens at ...................... Full Throttle Operating Range ...............

4 - In-line 4.000 in. x 3.60 in, 181Cu. in. (3.0 Liter) 1- 2- 3- 4 1- 3- 4- 2 9.3 to 1 160° F 4200-4600 RPM

2. Engine Dimensions, Fits and Adjustments Pistons: Type ................................ Clearance Limit at Top Land .............. Clearance Limit at Skirt .................. Compression Ring Groove Depth .......... Oil Ring Groove Depth ..................

Flat Head 0.0255 - 0.0345 in. 0.0025 - 0.0035 in. 0.209- 0.211 in. 0.190 - 0.199 in.

Piston Rings: Compression Ring Material ......................... Type ............................ Coating - Upper Ring ............... Coating - Lower Ring ............... Width ........................... Gap ............................ Oil ring Material ......................... Type ............................ Coating (rail) ..................... Width (Piston Groove) .............. Gap {Ring) ....................... Width (Ring) ...................... Expanders .......................

Cast iron Radius Face (Upper) Tape Face (Lower) Molybdenum Wear Resistant 0.0775 - 0.0780 in. 0.010 - 0.020 in. (Upper) 0.013 - 0.025 in, (Lower) Flat Spring Steel Multi-piece RaiJ Expander and Spacer Chrome 0.188 - 0.189 in. 0.015 - 0.055 in. 0.154 - 0.160 in. One-Piece Expander-Spacer

Piston Pins: Length .............................. Diameter ............................. Clearance in Piston (new) ................ Wear Limit in Piston .................... Clearance in Rod .......................

2.990 - 3.010 in. 0.9270 - 0,9273 in, 0.0003 - 0,0004 in. 0.001 in, 0.0008 - 0.0021 in.

2-42

Er~ine/er~

EngineSpecifications Connecting Rods: Material .............................. Length CL to CL ....................... Connecting Rod Bearing Material ......................... Effective Length ................... Clearance ........................ End Play .........................

Drop Forged Steel 5.700 in. M400 0.792 - 0.822 in. 0.00085- 0.00135in. 0.008 - 0.015 in.

Crankshaft: Material ............................. End Play ............................. End Thrust Taken By .................... Crankpin Journal Diameter ............... Main Bearing Type ............................ Journal Diameter .................. Length .......................... Clearance ........................

Nodular Cast Iron 0.002 - 0.006 in. Rear Main Bearing 2.099 - 2.100 in. Precision Removable 2.2983- 2.2993 in. 0.822 in. (rear) 0.830 in. (others) 0.0003- 0.0029 in.

Camshaft: Camshaft Bearing Material ......................... Steel BackedBabbitt; Journal Diameter x Bearing Length .... 1o8692in. x .860 in. Bearing Outer Diameter - Nos. 1 and 2 . 1.999 - 2.001 in. Bearing Outer Diameter - No. 3 ....... 2°009- 2.011 in. Type of Drive ......................... Gear Crankshaft Gear Material ................ Helical Cut Nodular Cast iron Camshaft Gear Material ................. Helical Cut Bakelite and Fabric Composition Lobe Lift ............................. 0.253 in. _+ 0.005 in. Valve Systems: Lifter Type ........................... Rocker Arm Ratio ...................... Valve Lash Adjustment Intake and Exhaust (hot) ............ Valve Face Angle ...................... Valve Seat Angle ....................... Stem to Guide Clearance Intake ’Valve ...................... Stem to Guide Clearance Exhaust Valve .................... RecommendedValve Seat Width Intake ........................... Exhaust .........................

Hydra~uJic 1.75 to 1 3~ to 1 Turn DownFrom "Zero Lash" Point °45 = 46 0.001(],- 0.0027in. 0.0010- 0.0027 in. lh2 in, to I/~6 in. Vie in. to s~2in.

EngineSpecifications Valve Systems(cont.): Outer Valve Spring Free Length ........... Outer Valve Spring Pressure Lb. @ in ......................... EngineLubrication:

2.08 in. 78-86 @1.66 in.

Type Oil Pump ........................ Normal Oil Pressure .................... Crankcase Capacity- Quarts ..............

Gear 40-60 PSi @ 2000 RPM 31~ (4 with newfilter)

Oil Grade Recommended:Service SG-Meeting GMSpec 6094 SAE 30 32° F. and Above ....................... SAE 20W-20 0° F. to 32° F ........................... Below 0° F ............................ SAE 10W WerecommendDuraPlus Synthetic Motor Oilwhich is specially formulated for heavy duty marine use. DuraPlus Synthetic Motor Oil provides superior anti-wear qualities, especially important during prolonged high speed operation, nt also neutralizes acids created in aim internal combustion engines. This motor oil is formulated to offer superior protection against corrosion and to resist oxidation and high temperature sludge formation° The use of multi-viscosity oils is not recommended.Disregard any reference to multi-viscosity oil printed on engine. Such reference is intended for automotive use only, not marine use. Fuel Grade Recommendation ..............................

2-44

See General Information section

Engirteleng

TorqueSpecifications- All Models The following specifications

are for screw sizes not shownotherwise:

SCREW SiZE No. 6 No. 10 No. 12 1/4 ~6 ¾

FT. LBS

IN. LBS.

N.rn

2- 3 3-4 5- 7 10- 12 18 - 20

7- 10 25- 35 3;5-45 60 - 80 120- 140 220 - 240

0,8- 1 :3 - 4 4-5 7- 9 14- 16 24 - 27

Use a reliable torque wrenchto tighten the parts listed to prevent straining or distorting the parts or possibly damagingthe threads. These specifications are for clean threads only. Dirty threads produce friction which prevents accurate measurement of tightness, it is important that these torque specifications be strictly observed. Overtightening to any extent maydamagethreads, thus preventing proper torque from being obtained, requiring replacement or repair of the damagedpart.

E~

Adaptor- Oil Pressure Sender Alternator - Bracket to Engine Camshaft Thrust Plate Circulating Pump Crankshaft Oil Seal Retainer Distributor Clamp Exhaust Elbow Flywheel Beilhousing Flywheel Cover Front Mount - Port Front Mount - Starboard Oil Pan (1/4 x 20) Oil Pan(5/16 x 18) Oil PumpCover Oil Withdrawal Tube Fitting Power Steering PumpBracket Starter Motor Starter Motor Bracket Raw-water Pump Bracket Thermostat Housing Timing Chain Cover Valve Cover

{ FT. LBS.} (ON.LBS.}

10-14 26-30 13-17 20 12-14 28-36

72-90 135 60-84

48-56 32-40 80 165 65-75 15-18 26-30 30-36 16-19 13-17 12-16 -

8O 65

14-19 35-41 8-10 18-23 15,3 27 16-19 38-49 7-9 65-76 43-54 9 18,6 7-8 20-24 35-41 41-49 22-26 18-23 16-22 9 7,3

TorqueSpecifications - (Cent,) ( FT. LB$. } ( iN. LBS. ]

Connecting Rod Cap CrankshaftOil Seal Retainer FlameArrestor Cover Flare - Oil WithdrawalTube Flywheel and Coupler Flywheel Bellhousing intake/Exhaust Manifold

35 15-18 40-45 35-40 20-25

47 15,3 3,4-4,5 20-24 54-61 47-54 27-34

35 65 95 20-25 60-7O

47 88 129 27-34 81-95

135 30-40

Cylinder Head Step 1 Step 2 Step 3 Intake/Exhaust Manifold MainBearing Cap(exc. rear) Main Bearing Cap, Rear Step 1 Step 2 Oil Pump

{~

10-12 60-70

110-120

14-16 81-95 12-14

FlameArrestor to Carburetor Flywheel and Coupler PowerSteering PumpBracket

10-15 13-15

65-80 -

7-9 14-20 18-20

Oil Filter Retainer - Oil PanDrain Sender,Oil Pressure Sender, Water Temperature Spark Plugs

Oneturn after contact 1 5-18 20-24 10-14 14-19 I8-22 24-30 20 27

2-46

E.~i./er~

Section3 4.3 GL, GS, Gi 5.7 GL, Gi Volvo Penta Engines

Table of Contents

Balance Shaft Service - V-6 ............ 3-17 Balance Shaft Bearing Replacement..... 3-20 Camshaft ............................ 3-20 Camshaft Lobe Lift, Measuring ......... 3-26 Circulating Pump..................... 3-38 Connecting Rod Bearing Replacement... 3-31 Crankshaft ........................... 3-28 Cylinder Block ........................ 3-36 Cylinder Head ........................ 3-10 Engine Coupler Replacement........... 3-42 Engine Specifications ................. 3-45 Exhaust Hose Replacement ............ 3-41 Exhaust Manifold .......... ............ 3-5 Exhaust (Flapper) Valve Replacement... 3-42

Front Engine Moun",s .................. General Specifications ................. High-Rise Exhaust Elbow Replacement.. Intake Manifold ........................ Intermediate Pipe Fleplacement ......... Lubrication System.................... Oil Pan .............................. Oil Pump............................ Oil Seal, Rear Main Bearing ............ Piston, Ring and Connecting Rod ....... Timing Chain and Sprocket ............. Torque Specifications .................. Valve Lifter, Hydraulic .................. Valve Spring and Seal Repair ............

Safety Warnings Before working on any part of the engine, read the section called Safety at the end of this manual. Unless instructed otherwise, always disconnect the battery cables from the battery before working on electrical systemto prevent possible sparks or arc, ing in the enginecompartment. Before starting engine after repair or maintenanceprocedures, alwaysmake sure enginecompartment is free of fuel vaporsto prevent possible fire and explosion. Whenworking on an engine that is running or being cranked, use extreme care to avoid getting hands, fingers or clothing caught in the alternator, power steering pump, supply pump, and circulating pUmprbelts, pulleys and other movingparts.

Entline/eng

3-1

3-39 3-44 3-40 3-3 3-41 3-23 3-24 3-24 3-27 3-32 3-15 3-47 3-6 3-9

General Motors Tools Item

Part Number

Air Line Adaptor .............................. Balance Shaft Bearing Service Kit ................. Bearing Puller ............................... Bearing Remover .............................. Carbon Remover ............................... Crankshaft SeaFInstaller ........................ DamperPuller and installer ...................... Dial indicator Set ............................... Dial Indicator .................................. Driver Handle ................................. Volvo Penta AmphenolCrimping Tool ........... Pin Remover& installer ......................... ReamerTool Set ............................. Reamer0.003 in. O.S ............................ Reamer0.013 in. O.S ............................ Ring Compressor ............................... Seal Installer ................................. Seal Installer ................................. Shaft installer ................................ Spring Tester .................................. Stud Installer .................................. Stud Protector ................................. Stud Remover ............................... Vacuum Pump .............................. Valve Guide Cleaner ............................ Valve Spring Changer ......................... Valve Spring Compressor ........................

J-23590 J=38834 J-6098-01 J-26941 J-8089 J-35468 J-39046 J-8520 J-8087 J-8092 P/N 322696 J-24086 J-5830-02 J-5715 J-6036 J-8037 J-35468 J-35621 J-36996 J-8056 J-6880 J-5239 J-5802-01 J-23738-A J-8101 J-5892-C J-8062

OrderDirectly from: Kent-MooreTool Division 28635 Mound Road Warren, MI 48092 1-800-345-2233 Price and ordering information are available from Kent-Moore Tool Division.

Material Required DuraPlusSynthetic Motor Oil or equivalent MolykoteLu b rica nt Plastigage (Green) Gasket Sealing Compound GMSilicone Rubber Sealer Liquid Neoprene For additionamservice information not coveredin this manual, obtain the appropriate ChevroletEngineWorkshopManualfrom: HelmInc. P. O. Box 07130 Detroit, MI 48207

3-2

Engine/eng

intake Manifold Removal [1~ EEl 1. Drain coolant from both sides of block and manifolds. 2. Disconnect: ~/~ a. Battery cables from battery. b. Coolant hoses at thermostat housing.

28287

~. Throttle cable from carburetor/TBI unit and anchor block. d. Crankcase ventilation sides).

hose from rocker arm covers (both

e.Wire at temperature gauge sender unit wiring harness from alternator.

and e,ngine

f. Distributor high tension and ignition primary leads from coil. 5.7 Gi: Disconnect 2-wire connector (brown and pink) from the distributor. 3. Remove: Distributor cap and mark the position of the rotor on the housing. Scribe a line on distributor housing and i!ntake manifold for reassembUyin the same position. Remove the distributor. b. Alternator" and alternator mountingbracket from engine. c. Carburetor/TE}l unit fuel line from carburetor/TE}l unit and fuel pump(s). d. Oil pressure sending unit. e. Manifold attaching bolts and solenoid bracket. Lift manifold from engine. Discard front and rear seals and gaskets. f. ff manifold is to be replaced, transfer: carburetor/TBI unit, thermostat and housing (use new gasket), throttle cable anchor bnock assembly, distributor clamp and temperature sending unit. Transfer additional hardware as required.

25916

Installation 1. Clean gasket and seal surfaces on manifold, block and cylinder heads. 2. Install: a. Newmanifoldseals on block andnewgasketson cyfin-der heads.Usesealer at water passages and whereseals butt to gaskets. i

[33 Note IOn those enginesnot havingfront andrear manifoldseals,

DR225

place a 3/16 in. beadof GMSiUiconeRubberSealer on the front and rear ridges of the cylinder case. Extendthe bead1/2 in. up eachcylinder headto seal andretain the manifold side gaskets. V-6 Models Tightenall bolts except®to 35 ft. Ibs. (47 N-m)followingsequenceshown.Tighten@to 41 ft. Ibs. (56 N-m).

EEl V-6 Modelswith ribbed aluminumoil

pan. Tightenall bolts in sequence usingthree steps. a. 27in. lb. (3 N-m). b. 106in. lb. (12 N-m). c. 132in. lb. (15 N-m). V-8 Models Tightenall bolts to 89 in. Ibs. (10 N-m).

t

c.Distributor with rotor andaligned exactly as markedduring removal. Note!If enginewascrankedwhile distributor wasout, completeignition timing proceduremustbe followed. Seethe appropriateIgnition Circuit in Electrical/Ignition Systems ServiceManual. d. Alternator with mountingbracket. e. Distributor capandhigh tensionleads. Seethe GeneralInformationsectionin Electrical/Ignition ServiceManual for correct firing orderandsparkplugwire routing. f. Oil pressuresendingunit. 3. Connect: a. All electrical connections.ApplyBlackNeoprene Dip on all exposedconnections. b. Carburetor fuel line. c. Throttlecable. d. All waterhoses,andcloseall drain petcock. e. Bothcrankcaseventilation hoses. f. Batterycables. 9. Start engine.Adjustignition timing, carburetoridle speedand mixture. Check for leaks. SafetyRelated

3-4

Engine/eng

Exhaust Manifold Removal 1. Drain water from exhaust manifolds. 2. Disconnect water hose from manifold. 3. Loosen upper exhaust hose damps, then remove higlh rise elbow. 4. Removemanifold attaching nuts and washers. Discard nuts. inspection 1. inspect for cracks. 2. To pressure check manifold, use a fabricated plate as pictured ~) and a new elbow gasket (~) to seal water passage manifold. Be sure to apply sealer to gasket. Install rubber drain caps to manifold and secure with clamps. Attach a Volvo Penta pressure gauge © to the water inlet hose. A bushing can be made to secure pressure gauge to hose. With the pressure gauge attached to the manifold, submergemanifold in water. Pressurize the manifold to 10-15 PSi (22-25 kPa) and check for leaks. Manifold should not leak around clampsand plate. If so, retighten clamps or reseal plate. No drop in pressure should be realized.

--__51

DR2642

installation 6~ ~] 1. Clean mating surfaces on manifold and head. Install new exhaust gasket, then install manifold and secure with new Iocknuts and washers. Tighten nuts ~) to 20-26 ft. Ibs. (27-35 N.m). 2. Install a newgasket and high rise elbow to manifold. Tighten bolts to 12-18 ft. Ibs. (16-24 N-m). 3. lnstalt

V-6 Models 28287

exhaust hose and secure with clamps.

4. Connectwater hose. install

and tighten drain petcocks.

5. Start engine and checkfor fuel leaks.

25916

HydraulicValve Lifter Checking HydraulicValveLifter Whencheckinghydraulic valve lifters, remember that grit, sludge, varnish, or other foreign matterwill seriously affect their operation. If any foreign substanceis found in the lifters or engine whereit maybe circulated by the lubrication system, a thorough cleaning job mustbe doneto avoid a repetition of lifter trouble. To help preventlifter trouble, the engineoil andoil filter mustbe changedas recommended in General information section. The engine oil must be heavy-duty type (for Service SG) and must also conform to General Motors Specification 6094Mto avoid detrimental formation of sludge and varnish. Werecommend Volvo Penta DuraPlus" Synthetic Motor Oil. The boat owner should be specifically advised of these requirements whenthe unit is delivered. Faulty valve lifter operation usually appears under one of the following conditions: 1. RappingNoiseOnly WhenEngineis Started: When the engineis stopped,any lifter on a camshaftlobe is under pressureof the valve spring; therefore, leak downor escapeof oil from the lower chambercan occur. Whenthe engine is started, a fewseconds maybe requiredto fill the lifter, particularly in colder weather, if noise occurs only occasionally, it maybe considered normal, requiring no correction. If noise occurs frequently, however, checkfor either oil too heavyfor prevailing temperatures,or excessivevarnishin lifters. 2. intermittent RappingNoise: An intermittent rapping noise that appearsand disappearsevery few secondindicates leakage at check ball seat due to foreign particles, varnish, or defective surface of checkball or seat. Replacelifters as necessary. 3. Noiseat Idle and LowSpeed: if one or morevalve lifters are noisy at idle speedand up to approximately 1200RPM,but quiet at high speeds, it indicates excessiveleak downrate or faulty checkball seat or plunger. With engine idling, lifters with excessive leak downrate maybe spotted by pressing downon eachrocker arm abovethe push rod with equal pressure. Reconditionor replace noisy lifters.

3-6

Engine/eng

4. GenerallyNoisyat All Speeds: Checkfor low or high oil level in crankcase.Highoil levels will be c, hurnedby crankshaftandwill force air bubblesinto the lifters. Low oil levels allow pump to pumpair at high speed.With engineidling, strike each rocker’ arm abovethe push rod several sharp blows with a mallet; if noisedisappears,it indicates that foreign material waskeepingcheckball from seating. Stop engineandplace lifters on camshaftbasecircle. If there is lash clearancein anyvalve linkage,it indicatesa stucklifter plunger,wornlifter bodylower,end, or worncamshaftlobe.

,,,~/

5. LoudNoiseat NormalOperatingTemperatureOnly: I1: a lifter developsa loud noisewhenthe engineis at normaloperating temperature, but is quiet whenengineis below normaltemperature, it indicates an excessivelyfast leak downrate of scored Nfter plunger.Recondition or replacelifter. Removal

¯ .~. ~ // ~ ~-.-:-....~

y..,,,--

,,

1. Withair hoseandcloths, cleandirt fromcylinder headsandadjacent parts to avoidgetting dirt into engine.It is extremelyimportant that nodirt getsinto the valvelifters. 2. Remove intake manifold. Remove exhaust manifold. ET1 3. Remove rocker armcovers. Do not pry, if covers stick use rubber mallet andstrike cover end to jar loose. Loosenrocker arm nuts or screwsandpivot the rocker arms@free of the pushrods. [:3[] 4. V-6 Models: Removepush rods ®. Unscrewretainer @ with restrictors @.Remove lifters that require service. 5. V-8 Models: Remove push rods ® and removevalve lifters 6:) that require service. Placelifters in a wooden block havingnumbered holes or use other suitable meansof identifying themaccordingto original position in the engine. E2~ 5.7 Gi Models: Removepush rods ®. Unscrewretainer with restrictors @.Remove lifters that require service.

@

ROTATING - NORMAL, OK - NOTROTATING

6. If less than a completeset of lifters is being removed,immediately disassemble oneor twofor presence of dirt or varnish.If lifters containdirt or varnish, it is advisableto remove aNlifters for replacement.Otherwise,it will be satisfactory to service only those lifters that are not operatingproperly. E4~7. Examine the camcontact surface at lower endof lifter body. If this surface is excessively worn, galled or otherwise damaged, discard the lifter assembly.In this case, also examinethe mating camshaftlobe for excessive wearor damage.

E n9ine/er.,g

3-7

GALLED- SHOULD BE REPLACED - SOFT, WORN

Installation Note i Before installing anynew lifters, coatthebottom of thelifter with Molykote or its equivalent. 1. Bnstall valvelifters in cylinder block. If anynewlifters or a new camshafthas beeninstalled, an additive containing EPlubricant such as G.M. Engine Oil supplementmust be addedto the crankcaseoil. 2. V-6 ModelsOnly: Install retainer with restrictors. Tighten retainer bolts to 145in. Ibs. (16,4 Nm). 3. Install pushrodsonto lifters. Install intake manifold. 4. Pivot rocker armsin place. V-6 ModelsOnly:Tighten screwsto 40 ft. Ibs. (54 Nm).V=8ModelsOrfly: tighten the adjusting nuts zero lash. Valve LashAdjustment - V-8 only 1. Baroverthe enginecrankshaftuntil markon harmonic balancerlines up withcenterof "0" markonthe timingtabto achieve ’q-DC"(TopDead Center). Thismaybedetermined bythe valvesfor number 6 cylinderrocking,andboth valvesfor number 1 cylinderareclosed.If thevalvesfor number 1 cylinderare rockingandthe valvesfor thenumber 6 cylinderare dosedtheenginecrank°shaft . shouldberotated360 E~2. Valveadjustment is made by looseningthe rockerarmstudnut until thereis playin thepushrodandthentightenslightly to remove anyfreeplayof thepushrod. Thismaybedetermined byrotatingpushrod,with fingersasthe nutis tightened.When thepushroddoesnotreadilyrotate,the clearance has beeneliminated.Theadjustingnut shouldbetightenedoneadditionalturn °) to placethelifter plunger (360 in thecenterof its travel.Nofurtheradjustmentis required.Withtheengine in this position,thefollowingvalvesmaybe adjusted.

DR2104

Exhaust1,3, 4, 8 Intake- 1,2,5, 7 °) until the timingmarkis at "TDC" 3. Crankthe engineonerevolution(360 again.Thisis number 6 firing positionandcanbeverifiedbycylindernumber 1 valvesrockingandboth the number 6 cylinder valvesclosed.Withthe engine in this position,thefollowingvalvesmaybeadjusted. Exhaust - 2: 5, 6, 7 Intake- 3, 4, 6, 8 4. Install rockerarmcoverswith newgaskets. V-6Models:Tightenscrewsto 62-115in. Ibs. (7-13 Nm). V-8Models:Tightenscrewsto 45 in. Ibs. (50 Nm). 5. Install exhaust manifold. Start engine andcheck for oil leaksat rockerarm covers. 3-8

Englne/e~

[~ Do not attempt to turn the adjusting nut one full turn while the engine is operating. Adjustment in this mannerwill not allow the lifters to bleed down. This would result in valve train damage, probably bent push rods. For those who prefer to adjust the valve lash while the engine is running, the preferred methodwould be to find the "zero lash" point as described aboveand then ,,;lowly turn the adjusting nut 1/4 turn. Wait for the lifter to bleed down (several engine revomutions)and again turn adjusting nut 1/,~ turn. Continue this adjust and wait cycJe until nut is one complete turn down from "’zero lash" point. Repeat sequence on rem;~ining valves. DR2103

Valve Spring and Seal Repair Removal [2~ 1. Removerocker arm cover. ;!. Remove spark plug, rocker arm, and push rod on the cylinder(s) to be serviced. L~ 3. mnstall Air Line Adapter tooa J-23590 to spark pmugport and apply compressedair to hold the valves in place. ~-~ 4. Using tool J-5892-C to compressthe valve spring, remove tlhe valve locks, valve cap and vaave spring and damper. 5;. Remove the vaJve stem oil seal. Insta|iation 1. install

seal over valve stem and seat against head.

2. Set the valve spring and damper, valve shield and valve cap in place. Compressthe spring with tool J-5892-Cand install oi0 seal in the 0ower groove of the stem, makingsure the seal is fiat and not twisted. [No=~ A light

coat of oil

on the seal will

help prevent

twisting.

3. Install the valve locks and release the compressortool making sure the locks seat properly in the upper groove of the valve stem. Grease may be used to hold the locks in place while releasing the compressor tool 4. Using VacuumPumpJ-23738-A, apply vacuumto the va0ve cap to makesure no air leaks past the seal 5. Install spark plug and tighten to 22 ft. Ibs. (30 N-m). 6. Install

Engine/eng

and adjust valve mechanismas previousJy outlined.

3-9

Cylinder Head Removal 1. Drain water from block and exhaust manifolds. Removeintake and exhaust manifold. 2. Removevalve covers and spark plugs. 3. Loosen rocker arm nuts and turn rocker arms aside. Remove pushrods. if lifters are to be serviced, removethem at this point. Otherwise protect the lifters and the camshaft from the entrance of dirt by covering the area with clean cloths. 4. Removecylinder head bolts, cylinder heads and gasket. Place cylinder heads on bench, supporting them at each end on blocks of wood to prevent damageto gasket faces of heads. Disassembly 1. Removerocker arms nuts, ball seats and rocker arms. [~] 2. Using tool J-8062, compressthe valve springs and remove the valve keys. Release the compressor tool, and removerotators or spring caps, oil shedders, springs and spring dampers, then removeoil seals and spring shims. Somecylinder heads use exhaust valve springs with a shorter free length than the intake valve springs. 3. Removevalve from bottom of cylinder heads and place them and their respective valve springs in a rack in their proper sequenceso they can be assembledin their original positions. Cleaning [~ 1. Clean all carbon from combustion chambers and valve ports using tool J-8089,

DR3123

[~] 2. Thoroughly clean the valve guides using tool J-8101. 3. Clean all carbon and sludge from push rods and rocker arms. 4. Clean valve stems and heads on a buffing wheel. 5. Clean carbon deposits from head gasket mating surfaces. Inspection DR3124

1. Washall parts in cleaning solvent and dry them thoroughly. 2. Inspect the cylinder head for cracks in the exhaust ports, combustion chambers, or external cracks to the water chamber.

3-10

Engine/eng

3. Inspect the valves for burned heads, cracked faces or darnaged stems° [3 4. Measure valve stem clearance as follows: a. Clampa dial indicator on one side of the cylinder head rocker arm cover gasket rail. b. Locate the indicator so that movementof the valve stem from side to side (crosswise to the head) will cause direct movementof the indicator stem. The indicator stem must contact the side of the valve stem just above the valve guide.

¯ \

DR2101

c. Drop the valve headabout IAs in. (1,6 ram) off the. valve seat. d. Movethe stem of the valve from side to side using light pressure to obtain a clearance reading, if clearance exceedsspecifications, it will be necessaryto reamvalve guides for oversize valves. [5~ 5. Checkvalve spring tension with tool Spring Tester J-8056. [~ On all models, springs should be compressed and should check 76-84 poundsat 1.70 in. (34-38 kg at 43 ram) and 1!;)4-206 poundsat 1.25 inches (88-93 kg at 32 ram). Weaksprings affect power and economy and should be replaced if below 70 pounds (32 kg).

J 10375

Repair 1. Valve GuideBore: Valves with oversize stems are available for inlet and exhaust valves in the following sizes, 0.003 in., 0.015 in., and 0.030 in. (0,076, 0,381, 0,762 ram) (intake only). Use the reamer sizes from ReamerTool Set J-6830 to ream the bores for new w~lves.

860007

2. Rocker ArmStuds - V-8 Only: Rocker arm studs that have damagedthreads may be replaced with standard studs. If the studs are loose in the head, oversize studs, available in 0.003 in. or 0.013 in. (0,076, or 0,330 ram) oversize, maybe installed after reaming the holes as follows: [7---] a. Removeold stud by placing tool J-5802-01 ~) over the stud, installing nut and flat washerand removingstud by turning nut.

E.gl.~I..g

3-11

DR2105

b. Reamhole for oversize stud using ReamerJ-5715 for 0.003 in. (0,076 mm) oversize and Reamer J-6036 for 0.013 in. (0,330 ram) oversize. c. Coat press-fit area of stud with hypoid axle lubricant. install newstud using tool J-6880 ~). Tool should bottom on head. Do not attempt to install stud hole.

an oversize stud without reaming

3. Valve Seats:

DR2107

Reconditioning the valve seats is very important, because the seating of the valve must be perfect for the engine to deliver the power and performance built into it. Another important factor is the cooling of the valve heads. Good contact betweeneach valve and its seat in the head is imperative to ensure that the heat in the valve head will be properly carried away. Several different types of equipment are available for reseating valve seats; the recommendations of the manufacturer of the equipment being used should be carefully followed to attain proper results. Regardless of what type of equipment is used, however, it is essential that valve guides be free from carbon or dirt to ensure proper centering of pilot in the guide. a. lnstall expanding pilot in the valve guide bore and expandpilot by tightening nut on top of pilot. b,

C.

Place roughing stone or forming stone over pilot and just clean up the valve seat. Usea 46~ stone for both the inlet and exhaust valve seats. Removeroughing stone or forming stone from pilot, install finishing stone on pilot and cut just enoughmetal from the seat to provide a smooth finish.

d. Narrow downthe valve seats to the proper width for the intake and exhaust. See Engine Specifications. °This operation is done by grinding the port side with a 30 stone to lower seat and a 60° stone to raise seat. e. Removeexpanding pilot and clean cylinder head carefully to remove all chips and grindings from above operations. ~ Valve seats should be concentric (0,051 ram) total indicator reading.

to within

3-12

~~:~.

-~ ~m 1042~

0.002 in.

eo~i,~/~

4. Valves: Valves that are pitted can be refaced to the proper angle, en;~uring correct relation between the head and stem on a valve refacing machine. Valve stems which show excessive wear, or valves that are warped excessively should be replaced. Whena valve head which is warped excessively is refaced, a knifeedge will be ground on part or all of the valve head due to the amountof metal that must be removedto completely reface. Knife edges lead to breakage, burning or preignition due to heat localizing on this knife edge. if the edgeof the valve headis less than 1/3z in. (0,792 ram) thick after grinding, replace the valve. a.

If necessary, dress the valve refacing machine grinding °wheel to makesure it is smoothand true. Set chuckat 45 mark for grinding valves.

b. Clampthe valve stem in the chuck of the machine. c. Start the grinder and movethe valve head out in line with the grinder wheel by moving the lever to the left. d.Turn the feed screw until the valve head just contacts wheel. Movevalve back and forth across the wheel and regulate the feed screw to provide light valve contact. eo

Continue grinding until the valve face is true and smooth all around vamve.If this makesthe valve thin, the valve must be replaced as the valve will overheat and burn.

f. Removevalve from chuck and place stem in "V" block. Feed valve squarely against grinding wheel to grind any pit from rocker arm end of stem. Only the extreme end of the valve stem is hardened to resist wear. Do not grind end of stem excessively. g. After cleaning valve face and cylinder head valve seat of grinding particles, makepencil marksabout 1/4 in. apart across the valve face, place the valve in cylinder head and give the valve one-half turn in each direction while exerting firm pressure on face of valve. h. Remove valve and check face carefunly. If aal pencil marks have not been removedat the point of contact with the valve seat, it will be necessary to repeat the refacing operation and again recheck for proper seating. i. Grind and check remaining valves in the samemanner. Assembly [~ Whenreplacing valve springs, catalog for ordering information.

refer

to the latest

parts

r~ 1. Starting with number 1 cylinder, place the valves in the designated ports and assembleall but the seal and locks. Then, using tool J-8062, compressthe spring (~) and install the seal and locks ©. Seethat the seal is flat and not twisted in the valve stem groove, and that the locks seat properly in the valve stem groove. Notice that only the exhaust valves have rotators (~. [~ Place vane spring in position toward the cylinder head.

with the closed coil

end

[~ 2. Check the installed height of the vane springs, using a narrow, thin scale cut away at the bottom ~). Measurefrom the top of the shim, or spring seat, in the head to the top of the valve spring shield, if this is found in excess of 111/ls in. (42,86 mm), install a valve spring seat shim, approximately ~A6in. (1,59 mm) thick. At no time should the spring be shimmed to give an installed height of less than 13/4 inch (44 ram).

C03107

--®

Installation 1. Wipeoff engine block gasket surface and be certain no foreign material has fallen into the cylinder bores, bolt holes, or the valve lifter area. it is good practice to clean out bont honeswith an air hose. 2. fnstali new head gasket on cylinder bJock. Dowelsin the block will hold the gasket in position. Alwayshandle gaskets carefully to avoid kinking or damageto the surface treatment of the gaskets. DO NOTuse any type of sealing material on head gaskets. The gaskets are coated with a special lacquer to provide a good seal, once the parts have warmed up. This engine has special marine head gaskets. substitute automotive head gaskets.

47267

V-6 Models

Do not

I(o° 1 o

3. Clean gasket surface of cylinder head and carefulny set in place on the engine block dowel pins. 4. Clean and lubricate pound. InstalE bolts.

@@@@

the head bolts with Gasket Sealing Com-

[~ ~ 5. Tighten the head bolts with a torque wrench, in three progressive steps, following the sequenceshown.

N

DR2254

V-8 Models Step 1 - 25 ft. Ibs. (34 N-m) Step 2 - 45 ft. Ubs. (61 N-m) Step 3 - 65 ft. Ibs. (88 N.m)

47277

3-14

E~ine/eng

NoteI Damage to thecylinderblockthreads canresultif bolts arenotlubricatedwith Gasket SealingCompound prior to installationor if the bolts are tightenedexcessively.Usean accuratetorquewrench wheninstalling head bolts anddonotovertighten. Uneven tighteningof thecylinderheadbolts can distort the cylinderbores,causingcompression loss andexcessive oil consumption.

\

_

y

’Timing Chain and Sprocket Balancer and Cover Removal

]]

®

47287

1. Remove alternatorandpowersteeringbracketbolts. ;2. Remove drculatingpump pulley. 3. Remove harmonic balancerpulley bolts andpulley. [~ 4. tnstall tool J-39046 ®to harmonic balancer,andturn puller screwto remove balancerfromcrankshaft. 5. Draincoolingsystem anddisconnect hoseat circulatingpump. 47347

6. Remove circulating pump screwsandswingalternatorandpowersteering bracketsaside. Remove circulating pump anddiscardgaskets. 7. Remove timingchaincoverscrewsandcover. Notej V-6Models equippedwith compositecovers.Replacecoverwhen evercoveris removed, gaskets areintergral to coverandarenot servicable. Oil Seal Replacement 1. Pryoil sealoutof frontof coverusinga largescrewdriver. [~ 2. Install newseal with lip towardinside of cover. LJse tool J-35468 @to drivesealinto position. Timing Chain Replacement 1. Remove harmonic balancerandtimingchaincover. E~2. Crankengineuntil "O"markson camshaftandcrankshaftsprockets are in alignment. In this position, engine is timed to fire no.4 cylinder.

D c

’

o

3. Remove camshaftsprocketbolts. Remove sprocketandtiming chaintogether.Sprocket is a slight press-fitfor approximately 1/8inch.If sprocket does notcome off easily,a light blowwitha plastic-faced hammer ontheloweredge of thecamshaft sprocket shoulddislodgeit. E~4. Install timingchainoncamshaft sprocket.Holdthe sprocketvertical with thechainhanging below.Alignthecamandcranksprockettimingmarks, thenattachthechainto the cranksprocket.

47307

5o Align dowel in camshaft with dowel hole in sprocket and instanl sprocket on camshaft. Do not hammersprocket onto camshaft. This may loosen rear camshaft welsh plug. 6. Draw sprocket onto camshaft using the mounting bolts. 7. Lubricate the timing chain with engine oil. Timing Chain Cover Installation 1. Coat the cover gasket with sealer and place in position over dowel pins in cylinder block. 2. Lubricate timing cover seal lip with engine oil and place cover in position over dowel pins. 3. install bolts and tighten to 80 in. Ibs. (9 N.m). HarmonicBalancer installation 1. Coat timing chain cover seal area on balancer hub with engine oil. 2. Align keywayand start balancer on to crankshaft. [~ 3. Using appropriate end of tool J-39046 threaded into crankshaft, or a large washer and a zAs-20 × 4 in. bolt and nut threaded into center hole in crankshaft, tighten nut to seat harmonic balancer on crankshaft. 4. Removebolt and washer, anstall belt pulley and tighten screws to specifications. 5. Threadz/is-20 × 2 in. bolt and thick washerinto crankshaft and tighten to specified torque. 6. InstalJ circulating

34715

pumpand pulley. Attach water hose to pump.

7. Unstall aUternator and power steering pumpbrackets. 8. Instalm aJternator and powersteering belts and adjust tension to specifications.

3-1 6

Engine/eng

Balance Shaft Service - V-6 Only Removal lP. Remove distributor per instructions in the appropriatesection in Electrical/Ignition SystemsWorkshopManual. Give special attention to markingposition of rotor in relation to distributor base andintake manifo!d. 2. Remove intake manifold and circulating pump. 34796

3. Remove screws securing pulley and harmonicbalancer. 4. UseDamperPuller J-39046to removeharmonicbalance r. 5. Remove oil pan. 6. Remove screws securing timing chain cover and remove cover. 1 Compositecover mustbe replaced whenremoved,integral gaskets andseals are not serviceable. ~ ~No~e

34797

~=~7. Loosenbalance shaft driven gear screw ~). [3~ [~ 8. Removethe two screws securing camshaft sprocket, then unscrewthe nut securing camshaftsprocket. Remove sprocket andtiming chain. Note .... I Whenremovingthe nut, the stud maycomeout with it. If this happens,separate the nut and stud after removingsprocket andtiming chain.

348O4

9. Remove balanceshaft drive gear. 10. Remove screw(loosenedearlier) securing balanceshaft driven gear, then removegear. L~ 11. Remove the two balance shaft retainer screws and remove retainer. [~ 12. Tapbalance shaft and front bearing assemblywith a soft faced hammeras shownto remove.

34802

/

-6] i ! 1"o

DR5010

Insta|lation [~ 1. Dip forward bearing in clean motor oil. mnstall balance shaft and bearing assembly using Driver Handle J-8092 and Shaft Installer J-36996. 2. install N.m).

retainer screws (~ and tighten to 120 in. Ibs. (14

3. With the balance shaft drive gear temporarily instalned, turn camshaft so its timing mark is straight up. Removedrive gear. DR5013

4. Install driven gear, then rotate balance shaft by hand to make sure there is clearance between the balance shaft and the lifter retainer. ReplaceJilter retainer if necessary. 5. install

balance shaft driven gear screwfinger tight.

6. Turn balance shaft so the timing mark on the drive gear points straight down. 7. Install the drive gear so the timing markis aligned with the timing mark on the driven gear. Secure drive gear with retaining stud. Tighten to 12 ft. Ibs. (16 N-m).

34802

[~ ~ Before installing the camshaft sprocket and chain, make sure the timing mark on the crankshaft sprocket points straight up and the marks (~ on the balance shaft gears are aligned.

DR5014

3-18

Eng|ne/eng

[4~ 8. Hold camshaft sprocket and chain with sprocket 1Liming mark pointing straight down. Place chain on crankshaft sprocket, makesure timing marks are aligned, position camshaft sprocket on stud and secure to camshaft with nut. 9. Install

the two camshaft sprocket-to-camshaft screws.

[5~ 10. Tighten the camshaft sprocket-to-camshaft nut to 21 ft. Ibs. (28 N.m}.

screws and

[6~ 11. Tighten the balance shaft driven gear-to-balance shaft ,,;crew to 15 ft. Ibs. (20 N-m)plus an additional 35 degrees.

34804

34806

34807

Balance Shaft Bearing Replacement The balance shaft and front bearing are serviced as an assembly. Whenservicing the rear bearing the engine must be removed from boat. Rear Bearing Removal 1. Removebell housing coupler and flywheel. ~] 2. Drive out balance shaft plug. [~ [~ 3. Removerear bearing using Balance Shaft Bearing Service Kit J-38834 and Bearing RemoverJ-26941.

DR5019

Rear Bearinglnstallstion [~ 1. Dip bearing in clean motor oil and install J-38834. El 2. Install 3. Install

with service kit

balance shaft plug.

bell housing coupler and flywheel.

Camshaft Removal 1. Removedistributor per instructions in the appropriate section in Electrical/Ignition Systems Workshop Manual Give special attention to marking position of rotor in relation to distributor base and intake manifold. 2. Removeintake manifold and circulating

pump.

3. Removerocker arm covers, valve lifters,

and push rods.

DR5012

4. Removepulley, harmonic balancer, timing chain cover, timing chain, and camshaft sprocket. V-8 Models Only: Removecamshaft thrust plate.

3-20

Engine/eng

!5. V-8 Models Only: Removefuel pumpand push rod. [4~ 6. Install two ~8-18 x 4 in. bolts in camshaft sprocket bolt holes and carefully pull out camshaft. Use care not to damage camshaft bearings. inspection The camshaft has five bearings, all with the samejournal diame1:or of 1.8692 in. to 1.8682 in. (4,7477 4,7452 cm). These dimensions should be checked with a micrometer for an out-ofround condition, if the journals exceed 0.001 in. (0,025 mm) out-of-round, the camshaft should be replaced. The camshaft should also be checked for alignment. The best methodis by use of "V" blocks and a Dial Indicator tool J-8520. The dial indicator will indicate the exact amountthat the camshaft is out of true. If it is out more than 0.002 in. (0,051 ram) dial indicator reading, the camshaft should be replaced. Whenchecking, the high reading of the dial indicator indicates the high point of the shaft. Examinethe camshaft bearings and if any bearing needs replacement, replace all bearings. Camshaft Bearing Removal Camshaft bearings can be replaced while engine is disassembled for overhaul, or without complete disassembly of the engi~ne. To replace bearings without complete disassembly, remove the camshaft and crankshaft leaving cylinder heads attached and pistons in place. Before removing crankshaft, tape threads of connecting rod bolts to prevent damageto crankshaft. Fasten connecting rods against sides of engine so they will not be in the way while replacing camshaft bearings. 1. With camshaft removed,drive out expansion plug at rear of the rear camshaft bearing. Drive it out from the inside. This procedure is based on removal of the bearing nearest center of the engine first. With this methoda minimumamountof llurns is necessary to locate the remover in position to remove next bearing. 2. install nut on puller screw and turn to end of threads on puller screw using tool J-6098-01. 3. index pilot

over screw with open end toward nut on puller

screw,

4. Insert remover with shoulder toward number3 bearing, making sure a sufficient amountof threads are engagedon the puller. !5. Using two wrenches, hold screw shaft with one wrench while !Iurning the front nut with the other wrench. After removing bearing from block, repeat operation for number2 bearing.

E,~i~,g

3-21

47317

6. RemovetooU and reassemble tool to remove number 4 bearing from rear of engine. 7. Assembleremover on driver handle and removefront and rear bearing. CamshaftBearing installation The camshaft front and rear bearing should be installed first. These bearings winl act as guides for the pilot and center the remaining bearings being pulled into place. [~ 1. Assembleremover and installer tool on driver handle and install camshaft front and rear bearings by driving towards center of cylinder block. 2. Using Tool Set J-6098, with nut then thrust washerinstalled to end of threads, index pilot in camshaft front bearing and install puller screw through pilot. 3. Index camshaft bearing in bore (with oil hole aligned as outlined below}, then install remover and installer tooJ on puller screw with shoulder toward bearing. o Numberone cam bearing oil hole must be positioned so that

oil

holes are equal distance

from 6 o’clock

47337

position.

Number two through number four bearing oil holes must be positioned at 5 o’cUock position (toward left side of engine and at a position even with bottom of cylinder bore). ¯ Number five position.

bearing oil

hole must be in 12 o’clock

EEl 4. using two wrenches, hold puller screw while turning nut. After bearing has been pulled into bore, removethe remover and installer tool from puller into bore, remove the remover and installer tool from puller screw and check alignment of oil hole in camshaft bearing. 5. install remaining bearing in the same manner, nt will be necessaryto index pilot in the camshaftrear bearing to instaUl the rear intermediate bearing. 6. Coat new camshaft rear plug O.D. with GMNo. 1052080 sealant, or equivalent, and install flush to 1/32 in. (0,792 mm}deep. Camshaftinstallation

47327

1. Lubricate camshaft journals with engine oil [~ Whenever a new camshaft is installed, lubricate the camshaft lobes with Molykote or its equivalent. Anso add one can of G.M. Engine Oil Supplementto crankcase oil. 2. instaln two ~6-18 x 4 in. bolts in camshaft bolt holes. Install camshaft, being careful not to damagebearing. V-8 ModelsOnly: install thrust plate. Tighten screwsto 105 in. Ibs. (11,9 N-m).

3- 2 2

Ertgine/eng

:3. Install sprocket and timing chain. 4. install timing chain cover, harmonic balancer, pulley and ,circumating pump. 5. V-8 Models Only: Install

push rod and fuel pump.

6. Connect coolant hose. 7. Install valve lifters,

pushrods, intake manifold and distributor.

8. V-8 ModelsOnly: Adjust valve lash. 9. Install rocker armcovers.

Lubrication System :Description and Operation The oil pumpconsists of two gears ~) and a pressure relief valve (~) enclosed in a two-piece housing ©, and driven from the ,distributor driveshaft whichin turn is driven by a helix gear on the .camshaft. It is flange mounted to the cylinder block with two bolts and piloted on the outside of the lower distributor bronze bearing. Oil passes through an opening in the mounting flange to the ,cylinder block, then into the full flow oil filter. The pumpcover is equipped with the pressure regulator valve that regulates oil pressure at approximately 40-60 PSi (276-414 kPa) at 2000 RPM. ~] The pump intake ~) is of the fixed screen type. A mesh screen filters out small particles of dirt and sludge which maybe present.

47357

A baffle incorporated on the intake screen has. been ,designed to eliminate pressure loss due to suddensurging stops. In the event that a screen becomes plugged, a steel grommet ,opens and bypasses oil to the pump. [~ A full flow oil filter is externally mountedto the cylinder block on the left side of the engine. Normally, all engine oil passes through the filter element; however, if the element becomes restricted, a spring loaded bypass valve (~) opens as mentioned above. The mainoil galleries run the full length of the crankcaseand cut into the valve lifter guide holes to supply oil at full pressureto the lifters.

E.gi~

3-23

DR2906

Therocker armsandvalves are lubricated by an oil channelin each pushrod. Excessoil drainsoff andreturns to the oil panthroughpassagesin the cylinder headandblock. Connecting passages drilled in the crankcase to permit delivery of oil at full pressureto all crankshaftandcamshaftbearings,distributor gear andshaft, the fuel pumppushrod, andthe timing chain. Holesdrilled in the crankshaftcarry oit fromthe crankshaftbearingsto the connectingrod bearings.Pistonsandcylinder walls are lubricated by oil forced througha small notchin the bearingparting surfaceon the connectingrod, whichregisters with the hole in the crankpinonce everyrevolution. Piston pins are lubricated by splash. Oil Pan Removag

DDEN)

1. Remove oil dipstick andwithdrawoil usinga suction pump. 2. Remove oil dipstick tube. Remove screws,oil panandgasket. ®

Installation [~ ~ ~] V-6 Models with ribbed aluminumoil pan. ~ Note~Thealignmentbetweenthe rear of the oil pan andrear of the engineblockis critical. Thetwosurfacesmustbe flush to prevent interfearenceof the flywheelhousingto enginefit. Usea straight edge andfeederguageth checkclearenceon three oil panto flywheel housing points as shown.If clearenceis greater than 0.010in.(0,254 mm) repeatprocedureuntil properclearenceis obtained. 1. Thoroughlycleanall gasketsealing surfaces. ApplyRTVsealer to the front andrear of the block. Applythe sealantabout1 in. in both directions fromeachof the four corners E~ v-6 Modelswith ribbed aluminum oil pan. Install gasket on block.Install oil pan.Tightenbolts to 18 ft. Ibs. (25 N.m)andnuts 17 ft. Ibs. (23 N.m)is sequence shown. V-6 Modelswith stamped shet metaloil pans°Install gasketon block. Install oil pan. Tighten1/4x20screwsto 80 in. Ibs. (9 N.m)and 16xl 8 screwsto 165in. Ibs. (18,6 N.m).

31576

E~] 3. Install dipstick tube fitting to pan; leavescrewloose. Orient fitting andattachdipsticktube.Thentightenfitting screwandflare nut. SeeTorqueSpecificationsat the endof this section for the torque figure. 4. Fill crankcase with engineoil.

3-24

Englne/eng

[2=2] 2. Remove pumpto rear main bearing cap bolt, and remove !pump,extensionshaft and collar. I~ Baffle bolts have to be loosened. :3. Disconnectpumpshaft from extension. .4. Remove four cover attaching screws,cover, gasket, idler gear ,and drive gearandshaft. !5. Remove pressureregulator valve andvalve parts. 6. if the pickup screen and pipe assemblyneedreplacing, mount the pumpin a soft-jawed vise andextract pipe from pump.IDo not disturb the pickup screen on the pipe. This is serviced as an assembly. "7. Washall parts in cleaning solvent and dry using compressed air.

47377

Inspection Should any of the following conditions be found during inspection operations, the pumpassemblyshould be replaced. 1. Inspect pumpbodyfor cracks and excessivewear. inspect oil pumpgears for excessive wear or damage. 2. Checkshaft for loosenessin the housing.Checkinside ot cover for wearthat wouldpermit oil to leak past the endsof gears. :3. Checkthe oil pickup screen for damageto screen or relief grommet= Checkfor oil in the air chamber. 4. Checkpressureregulator valve plungerfor fit in cover. Assembly and Installation 1. Place

drive

gear and shaft

in pump body.

2. Install idler gear so that smoothside of gearwill be towardthe (:over. 3. install a newpumpto cover gasket to ensure correct end clearanceof the gears. 4. install suction pipe and screenassemblyto cover and install {:over and attaching screws.Tighten screwsto 6-9 ft. Ibs. (8-12 N-m),andcheckto see that shaft turns freely. [3~ ~ if the pickup screen and pipe assembly was removed, it shouldbe replacedwith a newpart. Lossof press fit condition could result in an air leak and loss of oil pressure. Mountthe pumpin a soft-jawed vise, apply sealer to endof pipe, and using Tool J-8369tap the pipe in place with a plastic hammer.

DR2099

5. Install

regulator valve plunger, spring and retainer and pin.

6. Assemble collar end of extension shaft assembly over pump driveshaft, aligning tang of extension shaft with slot in end of pumpdrive shaft. 7. Assemblepumpand extension shaft to rear main bearing cap, aligning slot on top end of extension shaft drive tang on lower end of distributor driveshaft. 8. Tighten baffle bolts. [~ Oil pumpshould slide easily into place, if not, remove and relocate slot or locate other problem. 9. install tube.

oil pan using new gaskets and seals. Connectoil drain

Measuring Camshaft Lobe Lift 1. Removethe valve mechanismas previously outlined. E~ 2. Position indicator with ball socket adapter (Tool J-8520) push rod. Makesure push rod is in the lifter socket. 3. Rotate the crankshaft slowly in the direction of rotation until the lifter is on the heel of the camlobe. At this point, the pushrod will be in its lowest position. 4. Set dial indicator on zero, then rotate the crankshaft slowly, or attach an auxiliary starter switch and "bump" the engine over, until the push rod is fully raised position. Wheneverthe engine is cranked remotely at the starter, with a special jumper cable or other means, the distributor primary meadshould be disconnected from the distributor coil. Gi Models: Remove2 wire (pink and brown) connector from distributor. 5. Comparethe total lift specifications.

recorded from the dial indicator

/. /

D~I~

with

6. if camshaft readings for all lobes are within specifications, removedial indicator assembly. 7. Install

and adjust valve mechanismas outlined.

3-26

I:~ine/eng

Rear Main Bearing Oil Seal Replacernent Care should be taken when removing the rear crankshaft oil seal so as not to nick the crankshaft sealing surface. 1. Removeflywheel and oil pan. [2~ 2. insert a screwdriver into the notches provided in the seal retainer and pry the seal out. Take care not to damagethe crankshaft sealing surface. 3. inspect chamfe~on crankshaft for grit, Correct as necessary.

loose rust, and burrs.

4. Clean seal running surface on the crankshaft abrasive cleaner.

with a non=

5. Lubricate the inner and outer diameter of newseal with engine oH. [~] 6. install the seal on Seal installer J-35621. Position installer against the crankshaft. Thread the attaching screws into the tapped holes in the crankshaft. 7. Tighten the screws securely with a screwdriver. This will ensure that the seal is installed squarely over the crankshaft.

DR1879

8. Turn the handle until it bottoms. Remove installer. Oil Seal Retainer Replacement [~ 1. Removescrews, nuts and seal retainer ~). 2. Removegasket. 3. Remove rear crankshaft oil seal as previously stated. DR1881

4. Clean gasket su~aces on block and seal retainer. Whenever the seal retainer is removed, a new re~Lainer gasket and rear crankshaft oil seal must be installed. L~ 5. Attach gasket ® to the block. It is not necessary to use sealant to hold the gasket in place. 6. install seal retainer, screws and nuts. Tighten screws and nuts to 135 in. Ibs. (15,3 N-m). 7. Install oil pan. install previously.

rear crankshaft oil seal as oulIlined

8. Install flywheel.

E~i../o.~

3-27

Crankshaft Description Mainbearingsare of the precision insert type and do not utilize shims for adjustment, if clearancesare found to be excessive, a newbearing, both upper and lower halves, will be required. Bearingsare available in standardsize and 0.001in., 0.002 in., 0.010in. and0.020in. (0,025, 0,051, 0,254, 0,508ram)undersize. Selective fitting of both rod and mainbearings is necessaryin productionin order to obtain close tolerances.For this reasonyou mayfind one-half of a standardinsert with one-half of a 0.001in. (0,025 ram) undersize insert which will decreasethe clearance 0.0005in. (0,0127ram) from using a fuUl standardbearing. Whena production crankshaft cannot be precision fitted by this method,it is then ground0.009in. (0,229 ram)undersizeon only those mainjournals that cannotbe properly fitted. All journals will not necessarily be groundundersize. A 0.009 in. (0,229 ram) undersize bearing and 0.010 in. (0,254 mm)undersize bearing maybe usedfor precision fitting in the samemanneras previously described. If, for any reason, mainbearing caps are replaced, shimming may be necessary. Laminated shims for each cap are available for service. Shimrequirement will be determined by bearing clearance. inspection in general, (except No. 1 bearing) the lower half of the bearing showsa greater wearand the mostdistress from fatigue, if upon inspection the lower half is suitable for use, it can be assumed that the upperhalf is also satisfactory. If the lower half shows evidenceof wear or damage,both upper and lower halves should be replaced. Neverreplace one half without replacing the other half. To CheckCrankshaft: a®

b.

Removemain bearing caps and connecting rod caps and lift crankshaftout of cylinder block. Pushpistons to top of bores. Inspect the crankshaft. Number1 main bearing is ground to 2.4484- 2.4493in. (62,1894- 62,2122ram), number 3~ 4 bearings to 2.4481- 2.4490in. (62,1817- 62,2046 ram), number5 bearing to 2.4479- 2.4488in. (62,1767 62,1995mm),and crankpin journals are groundto 2.0988 - 2.0998in. (53,310- 53,335ram).

3-28

E~

These dimensions should be checked with a micrometer for out-of-round, taper or undersize. If the journals exceed0.001 in. (0,025 mm) out-of-round or taper, the crankshaft should replaced or reconditioned to an undersize figure that will enable the installation of undersize precision type bearings. The crankshaft should also be checkedfor runout. To perform this operation, support the crankshaft at the front and rear main bearing journals in "V" blocks, and indicate the runout of both the rear intermediate and front intermediate journals, using a dial indicator. The runout limit of each of these journals is 0.002 in. (0,051 mm). If the runout exceeds 0.002 in. (0,051 met), crankshaft must be repaired or replaced. Main Bearing Clearance ]’o obtain the mostaccurate results with Plastigage (or its equivalent), a wax-like plastic material which will compress evenly between the bearing and journal surfaces without damaging either surface, certain precautions should be observed. With the engine out of the boat and upside down, the crankshaft will rest on the upper bearings and the total clearance can be measured between the lower bearing and journal. [~ To ensure the proper seating of the crankshaft, all bearing cap bolts should be at their specified torque. In addition, preparatory to checking fit of bearings, the surface of the crankshaft journal and bearing should be wiped clean of oil. 1. With the oil pan and oim pumpremoved, and starting with the rear main bearing, remove bearing cap. (Note: Wipe oil from iournal and bearing cap before applying Plastigage materi,~l.) E~ 2. Place a piece of gauging plastic ~) the full bearing (parallel to the crankshaft) on the journal

width of the

Do not rotate the crankshaft while the gauging plastic is between the bearing and journal.

47397

3. Install the bearing cap and evenly tighten the retaining bolts to specifications. 4. Removebearing cap. The flattened gauging plastic found adhering to either the bearing shell or journal.

will

be

E2--~ 5. On the edge of gauging plastic envelope there is a graduated scale which is measuredin thousandths of an inch. Without removing the gauging plastic, measure its compressed width (at the widest point) with the graduations on the gauging plastic envelope.

47407

E!lgine/eng

3-29

Normally, main bearing journals wear evenly and are not out-of-round. However,if a bearing is being fitted to an out-ofround journal; 0.001 in. max. (0,025 ram) be sure to fit it to the maximum diameter of the journal, if the bearing is fitted to the minimum diameter and the journal is out-of-round 0.001 in. (0,025 mm), interference between the bearing and journal will result in rapid bearing failure. If the flattened gauging plastic tapers toward the middle or ends, there is a difference in clearance indicating taper, low spot or other irregularity of the bearing or journal. Be sure to measurethe journal with a micrometerif the flattened gauging plastic indicates more than 0.001 in. (0,025 mm)difference. 6. if the bearing clearance is within specifications, the bearing insert is satisfactory. If the clearanceis not within specifications, replace the insert. Always replace both upper and lower insert as a unit. If a newbearing cap is being installed and clearanceis less than 0.001 in. (0,025 mm),inspect for burrs and nicks; if none are found then install shims as required. 7. A standard size 0.001 in. or 0.002 in. (0,025 or 0,051 mm) undersize bearing mayproducethe proper clearance, if not, it will be necessary to regrind the crankshaft journal for use with the next undersize bearing. 8. Proceed to the next bearing. After all bearings have been checked, rotate the crankshaft to see that there is no excessive drag. [~ 9. Measure crankshaft end play (see Specifications) forcing the crankshaft to the extreme front position. Measureat the front end of the rear main bearing with a feeler gauge. 10. install a newrear main bearing oil seal in the cylinder block and main bearing cap. Main Bearing Replacement 1. Install a mainbearing removingand installing tool in oil hole in crankshaft journal. [~ if such a tool is not available, required to do the job.

47417

a cotter pin maybe bent as

2. Rotate the crankshaft clockwise as viewed from the front of engine. This will roll upper bearing out of block. 3. Oil new selected size upper bearing and insert plain (unnotched) end between crankshaft and indented or notched side of block. Rotate the bearing into place, and removetool from oil hole in crankshaft journal.

3-30

E~ine~ng

4. Oil newlower bearing and install !5. install engine.

in bearing cap.

main bearing cap with arrows pointing toward front of

6. Tighten main bearing cap bolts to specifications.

Connecting Rod Bearing Replacement Connecting rod bearings are of the precision insert type and do not utilize shims for adjustment. DO NOT FILE RODSOR ROD lAPS. if clearances are found to be excessive a newbearing will be required. Bearings are available in standard size and 0.001 in. (0,025 ram) undersize for use with standard size crankshafts. 11. With oiJ pan and oil pumpremoved, removethe connecting rod cap and bearing. ;!. inspect the bearing for evidence of wear or damage.(Be;arings showing the above should not be installed.) 3. Wipe the bearings and crankpin clean of oil. 4. Measurethe crankpin for out-of-round or taper with a micrometer. If not within specifications, replace or recondition the crankshaft. If within specifications and a newbearing is to be insltalled, measure the maximumdiameter of the crankpin to determine new bearing size required. 5. if within specifications, measurenew or used bearing clearances with the Plastigage material or its equivalent. If a bearing is being fitted to an out-of-round crankpin, be sure to fit it to the maximumdiameter of the crankpin. If the bearing is fitted to the minimumdiameter and the crankpin is out-of-round 0.001 in. (0,025 ram), interference between the bearing and crankpin will result in rapid bearing failure. a.

Place a piece of gauging plastic the full width of the crankpin parallel to the crankshaft. (Note: Surfaces must be free from oil.)

b. Install

the bearing in the connecting rod and cap.

c. Install the bearing cap and evenly tighten nuts to specifications. L~vQ_~Do not turn the crankshaft with the gauging plastic installed. d. Removethe bearing cap and using the scale on the gauging plastic envelope, measurethe gauging plastic width at the widest point.

Englr~/eng

3-31

6. if the clearanceexceedsspecifications select a new, correct size bearing and remeasure the clearance. 7. Coat the bearing surface with oil, install the rod cap and tighten nut to specifications. 8. Whenall connecting rod bearings have been installed tap each rod lightly (parallel to the crankpin) to makesure they have clearance. 9. Measurea[I connecting rod side clearances (see Specifications at end of this section), betweenconnecting rod caps.

47427

Piston, Ring and Connecting Rod Piston and Rod Removal 1. With oil pan, oil pumpand cylinder head removed, use a ridge reamer to remove any ridge and/or deposits from the upper end of the cylinder bore. Before ridge and/or deposits are removed, turn crankshaft until piston is at the bottom of stroke and place a cloth on top of piston to collect the cuttings. After ridge and/or deposits are removed, turn crankshaft until piston is at top of stroke and removecloth and cuttings. 2. Inspect connecting rods and connecting rod caps for cylinder identification. ’If necessarymark them.

/ J 5239

J 5239--

[~ 3. Removeconnecting rod cap and install tool J-5239 on studs. Push connecting rod and piston assembly out of top of cylinder block. It will be necessary to turn the crankshaft slightly to disconnect some of the connecting rod and piston assemblies and push them out of the cylinder.

DR3792

Piston and Rod Disassembly 1. Removeconnecting rod bearings from connecting rods and cap. If connecting rod bearings are being reused, pmacethem in a rack so they maybe reinstalled in their original rod and cap. 2. Removepiston rings by expanding them and sliding them off the pistons. Ring expandertools are available from Iocam automotive stores. 3. Using tools J-24086-20(~) and J-24086-8 ~), peaceconnecting rod and piston assembly in an arbor press with piston on support, then using remover, press piston pin out of connecting rod and piston. 4. RemoveassembJy from arbor press and remove tools, pin, connecting rod and piston.

3-32

piston

~13s Engme/eng

5. Clean varnish from piston skirts and pins with a cleaning solvent. DO NOTWIREBRUSHTHEPISTONSKIRT. Clean the ring grooves with a groove cleaner, and makesure oil ring holes and slots are dean. 6. inspect the piston for cracked ring Uands,skirts or pin bosses, wavy worn ring lands, scuffed or damagedskirts, or eroded areas at top of the piston. Replace pistons that are damaged or otherwise show signs of excessive wear. 7. Check fit of used piston pins. Use a dial bore gauge or tenescoping snap gaugefor the bore and a micrometer for the pin. Wearlimit on piston is production clearance plug 0.001 in. (0,025 ~. rnm). Replace piston and pin assemblyif wear is excessiw, Piston pins should be capable of supporting their own weight in either pin boss whencoated with light engine oil and at 60° F. Higher or lower temperatures will cause false indications. Piston pins are matchedfit to the piston and are not available separately. Piston pins will not becomeloose enoughto cause a knock or tapping until after prolonged use, and in such cases a new piston and pin assembly should be installed. Piston and Rod Assembly

]

94137

1. Lubricate piston pin holes in piston and connecting rod to facilitate installation of pin. ~4~ 2. Use J-24086-20, J-24086-9 and guide tools. Place connecting rod in piston and hoRdin place with piston pin guide ~ and piston pin ~). Place assemblyon fixture and support assembJy(~. L-~ 3. Using piston pin installer, J-24086-9 (~), press the piston pin into the piston and connecting rod. The piston pin installer is a variable insertion length tool. The insertion length is varied by rotating the hub on the shaft muchlike adjusting a micrometer. An alphanumeric scale is used to determine the desired length for a given piston pin assembly. After installer hub bottoms on support assembly, do not exceed 5000 PSi (34475 kPa) pressure, as this could cause structural damageto the tool. 4. Removepiston and connecting rod assembly from tool check piston for freedom of movementon piston pin.

and

94138

E~glne/eng

3-33

Piston Rings Piston rings are furnished in standard sizes as well as 0.030 in. (0,762 mm)oversize. Oil control rings consist of two segments(rails)

and a spacer.

Compressionrings are the deep section twist type, 3~2 in. (2,38 mm) wide. This type installed maintains diameter section.

compression ring takes it name, twist type, from its position which is cocked or twisted, it assumesand this position for life because the upper edge of its is chamfered, making the ring unbalanced in cross

All compression rings are marked with the metters "GM" cast in the upper side of the ring. Wheninstalling compression rings, makesure the side marked"GM" is toward the top of the piston. 1. Select rings comparablein size to the piston being used. l~ it is important that each ring be fitted to its individual cylinder for proper gap spacing, and to its individual piston and groove for proper groove clearance. 2. Slip the compressionring in the cylinder bore; then, using the head of a piston, press the ring downinto the cylinder bore about 1/4 in. (6,5 ram). Using a piston in this way will place the ring square with the cylinder wal~s. EEl 3. Checkthe space or gap betweenthe ends of the ring with a feeler gauge, if the gap between the ends of the rings is below specifications, removethe ring and try another for fit. Fit eachring separately to the cylinder in which it is going to be used. 4. New pistons, rings and cylinder bores wear considerably during seating and gaps widen quickly; however, engine operation will not becomeseriously affected if ring gaps do not become greater than 1/32 in. (0,792 ram}. 86OO48

5. Carefully removeall particles of carbon from the ring groove in the piston and inspect the grooves carefully for burrs and nicks that might cause the rings to hang up.

[2-~ 6. Slip the outer surface of the top and second compression ring into their respective piston ring groove, and roll the ring entirely around the groove to makesure the ring is free and does not bind in the groove at any point, if binding occurs, the cause should be determined and removed by carefully dressing with a 1Fine cut file. However,if the binding is causedby a distorted ring, install a newring. Piston Ring Installation ’1. install the oil ring spacer in the oil ring groove, and insert antirotation tang in oil hole. Hold spacer ends butted, and install steel rail on top side of spacer. Position gap at least one inch (2,54 cm) to left of spacer gap, then install secondrail on lower ,;ide of spacer. Position gap at least one inch to right of spacer gap.

10755

2. Flex the oil ring assemblyin its groove to makesure ring is free and doesnot bind in the groove at any point. If binding occurs, the cause should be determined and removed by carefully dressing with a fine cut file. However, if the binding is caused by a distorted ring, install a newring. :3. install second compression ring, then top compression ring and properly locate gaps. [~] 4. Proper clearance of the piston ring in its piston ring groove is very important in maintaining engine performance and in preventing excessive oil consumption. Therefore, when fitting new rings, the clearance between the top and bottom surfaces of the ring grooves should be inspected. 5. The upper compression ring should be fitted so that the clearance is 0.0012 in. to 0.0032 in. (0,0304 to 0,0813 ram). Clearance of lower compression ring is also 0.0012 in. to 0.0032 in. (0,0304 to 0,0813 ram). 6. Assemblethe rings to the pistons as they are fitted, and makea final test of the ring fit in the grooves by repeating the fitting procedure given above. Piston and RodInstallation 1. Lightly coat pistons, rings and cylinder walls with light engine oil. 2. With bearing caps removed, install bolts.

tool J-5239 on bearing cap

3. Instalm each piston in its respective bore, using tool J-5239 on each assembly. The side of the piston with the cast depression in the head should be to the front of the cylinder block and the connecting rod bearing tang slots facing side opposite camshaft. Guide the connecting rod into place on the crankshaft journals with the long detail of tool J-5239.

I’nglne/eng

3-35

860050

[~ Check position of ring end caps. They must not align with each other or the oil ring. El 4. Use tool J-8037 (~) to compressthe piston rings. 5. Install bearing caps and check the bearing clearance as described previously.

Cylinder Block inspection 47437

1. Checkthe cylinder block for cracks in the cylinder walls, water jacket and main bearing webs. [~ 2. Checkthe cylinder walls for taper, out-of-round or excessive ridge at top of ring travel. This should be done with a Dial Indicator J-8087. Set the gauge so that the thrust pin must be forced in about 1/4 in. (6,5 mm)to enter gaugein cylinder bore. Center gauge in cylinder, and turn dial to "0." Carefully work gauge up and down cylinder to determine the out-of-round condition, if cylinders were found to have more than 0.002 in. (0,051 mm)out-of-round, boring will be necessary. Cylinder Conditioning The performance of the following operations is contingent upon engine condition at time of repair. if the cylinder block inspection indicated that the block was suitable for continued use except for out-of-round or tapered cylinders, they can be conditioned by honing or boring and honing.

860053

if the cylinders were found to have less than 0.005 in. (0,127 ram) taper or wear, they can be conditioned with a hone and fitted with 0.001 in. (0,025 mm)oversize pistons. A cylinder bore of less than 0.005 in. (0,127 mm)wear or taper maynot entirely clean up when fitted to a 0.001 in. (0,025 mm)oversize piston, if it is desired entirely clean up the bore in these cases, it will be necessary to rebore for an oversize piston, if more than 0.005 in. (0,127 mm) taper or wear exists, they should be bored and honed to the smallest oversize that will permit complete resurfacing of all cylinders. Cylinder Boring 1. Before using any type boring bar, the top of the cylinder block should be filed off to remove any dirt or burrs. This is very important. Otherwise, the boring bar may be tilted which would result in the rebored cylinder wall not being at right angles to the crankshaft.

3-36

E.oi~,/~

2. Place the honeinto a cylinder bore, and expandthe stone~3until the hone can just be turned by hand. Connecta 1/2 in. (1,27 cm) electric drill to the hone, and drive hone at drill speed while moving hone up and down entire length of cylinder until hone begins to run free. During this operation, a liberal amount of kerosene should be used as a cutting fluid to keep the stones of the hone cmean. Move hone slowly up and down with rough stones, but movehone up and down rapidly enoughwith the fine stones to producea final bore finish of very fine surface scratches in a crosshatch pattern of approximately 45° to 65° included angle. The marks should be clean but not sharp, and free from embeddedparticles or torn or folded metal. 3. Expand the stones against the cylinder bore, and repeat the honing operation until the desired bore diameter is obtained. 4. Occasionally during the honing operation, the cylinder bore should be thoroughly cmeanedand the piston selected for the individual cymindercheckedfor correct fit. Thoroughly clean cylinder bores with soap and hot ,water to removeall grit particles. Piston Selection 1 CheckUSEDpiston to cylinder bore clearance as follows.: a. Measurethe "Cylinder Bore Diameter" with a tele,,=cope gauge21/2 in. (64 ram) from top of cylinder bore. b. Measurethe "Piston Diameter" (at skirt across centerline of piston pin). c. Subtract piston diameter from cylinder bore diameter to determine "Piston to Bore Clearance." d. Calculate piston to bore clearance and determine if piston to bore clearance is in the acceptable range. 2. If used piston is not acceptable, check if a new piston can be selected to fit cylinder bore within the acceptable range. 3. if cylinder bore must be reconditioned, measurenew piston diameter (across centerline of piston pin), then hone cylinder bore to correct clearance (preferable range}. 4. Markthe piston to identify the cylinder for which it was fitted.

[~ Handle the pistons with care, and do not attempt to force them through the cylinder until the cylinder has been bored to correct size as this type piston can be distorted through careless handling. 5. Thoroughly clean the cylinder bores with hot water and soap. Scrub well with a stiff bristle brush and rinse thoroughly with hot water. It is extremely essential that a good clean operation be performed. If any of the abrasive material is allowed to remain in the cylinder bores, it will rapidly wear the newrings and cylinder bores in addition to the bearings lubricated by the contaminated oil. The bores should be swabbedseveral times with light engine oil and a clean cloth then wiped with a clean dry cloth. Cylinders should not be cleaned with kerosene or gasoline. Clean the remainder of the cylinder block to remove the excess material spread during the honing operation.

Circulating Pump Description The Volvo Penta circulating pumpis manufactured specially for marine use. it is serviced only as an assembly. Do not replace with an automotive circulating pump. inspection 1. Removealternator

and power steering belts.

2. Grasp circulating pumppulley and check end and side play. Turn pulley to check for drag. 3. Look for water leaking from indicator hole beneath pumpshaft behind pulley. Replacepumpif play, drag, or leakage are evident. Removaland Installation 1. Drain water from block and disconnect circulating pump. 2. Removepulley. gaskets.

Removecirculating

water hose from

pump bolts,

pump and

3. Use new pumpto block gaskets and sealer. Install new pump assembly on cylinder block and tighten bolts as specified. 4. Install pulley, install alternator and powersteering belts, then adjust tension. 5. Install

hose to circulating pump.

6. Lake or tank test unit and checkfor leaks.

3-38

25929 Engff~e/eng

Front Engine Mounts Removal [3 1. Removetwo lag screws ~) and washers from mounts. L~ 2. Lift enginewith a hoist capableof lifting at least 1500 lb. (680 kg) to allow removalof front mountand bracket. [~ 3. Remove three mount screws and lock washers ®, Note screw lengths and location. [3 [~ Prior to disassembly of front mount assembly, measure distance and record measurement between large washer and flat on upper mount bracket.

25917

Disassembly [3 1. Removethree Iocknuts © and engine mount bracket ~) from mount bolt while holding bolt secure with socket (~). L=~ 2. Removetwo washers (~ and engine mount bolt mount.

~)from 11980

Reassembly E~ 1. Place small washer (~) on mount bolt and insert bolt through mount. Install large washer and secure with nut (i). Tighten to 60-75 ft. Ibs. (81-102 N-m). 2. install Upper inner nut and place engine mount bracket @ on engine mount bolt. Measuredistance between large washer and fiat on upper mount bracket. Adjust distance to recorded measurement. 3. install lock washerand top nut. Tighten nut to 100-120ft. Ibs. {136-163 N.m).

11979

installation DE] 1. Spray the engine mount screw threads with Loctite primer or equivalent and allow to air dry. AppmyLoctite or equivalent to the screws. Attach engine mount assembly to engine with three screws and washers. Tighten to 32-40 ft. Ibs. (43-54 N-m). EI~ 2. install

lag screws and tighten securely. 1197~

~1983

Height Adjustment [~ 1. To change engine height, tighten or loosen nuts (~) and as required. L~ 2. Lift enginewith a hoist capableof lifting at least 1500|b. (680 kg), Position engineat desired height, El 3. After setting mount position, turn upper inner nut ~) up against underside of engine bracket and hold nut with a wrench. Tighten top nut ~) to 100-120 ft. Ibs. (136-163 N-m). 2953

Any large adjustments to engine height should be fonlowed by a check of engine aRignment. Failure to check alignment could result in rapid engine coupler failure. See Drive Removal and Installation section of the Drive Unit/Transom Shield Workshop Manual for alignment procedures.

High-Rise Exhaust Elbow Repiacernent Removal [~ 1. Loosen two damps securing upper hose to elbow. Lubricate inside of hose with a soapy water solution.

34719

~] 2. Starboard Elbow: Removecircuit breaker bracket © and set aside. Removefour screws, flat washers, and lock washers mounting high-rise elbow. [~ 3. Use a soft hammerto free elbow from manifold. Use a twisting motion to pull elbow from hose. Removeand discard the elbow gasket. Installation 1. Thoroughly clean manifold gasket surface. Apply Gasket Sealing Compound to both sides of a new manifold gasket and place it on the exhaust manifold. [~ [~ 2. Lubricate the inside of the exhaust hose with a soapy water solution, insert the high-rise elbow into the hose with a twisting motion, and push it into hose as far as it wiIB goo [~ 3. Position elbow on manifold. Secure eabows and brackets with four screws, fiat washers, and lock washers. Tighten screws to 12-18 ft. Ibs. (16-24 N.m). Starboard Elbow: InstaBI circuit breaker bracket ©. [~ /~ 4. Slide clamps ® up onto hose and position two surface channels. Tighten clampssecurely.

Z~ Safety Related

them in the

3-40

34718

32371

32374

Exhaust Hose and intermediate Pipe Replacement Removal [8~ 1. Loosen eight clamps that secure the upper @and lower (~ exhaust hoses. tion,

2. Lubricate inside of lower hose with a soapy water" soluand slide lower hose down onto exhaust Y-pipe. 32375

L~ 3. Twist intermediate pipe out of upper hose. Lubricate inside of upper hose if necessary to ease removal. 4. Slide upper hose off high-rise exhaust Y-pipe.

elbow° Slide lower hose off

installation 1. Lubricate inside diameter of 3.5 in. (8,89 cm) i.D. lower hose with a soapy water solution. Slide it all the way onto the exhaust Y-pipe. [~ [~ The inside diameter of both the upper and lower hoses has a step (D 1.5 in. (3,81 cm) from one end. The stepped end of the hose must face the intermediate pipe wheninstalled. 2. Slide hose onto high-rise elbow untiU it seats. if hose is not properly positioned, it will not completely engagethe high-rise elbow or allow secure attachment. [~ 3. With a twisting motion, insert intermediate pipe all the way into the upper hose. Align lower end of pipe with exhaust Y-pipe, then slide lower hose up until it’s halfway onto the intermediate pipe.

32370

[8-7 ~ 4. Place four No. 68 clamps on upper hose. Plac|. = four No. 64 clamps on lower hose. Position clamps in channels and tighten securely.

32366

Exhaust(Flapper) Valve Replacement SX Models Removal 1. Removethe intermediate exhaust pipe following the procedure under Exhaust Hose and Intermediate Pipe Replacement. [~ 2. Slide the lower hose down far enoughto expose the valve pivot pin. Hold the valve while pulling out the pin, then lift out the valve. 32367

3. Inspect the two rubber bushings inside the pipe. Replace them if necessary. lnstaBation [~ 1. If installing new rubber bushings, apply Scotch Grip Rubber Adhesive to outside of tips, and insert into inside of exhaust pipe. [~ 2. Position valve with longest lip pointing down, and insert into pipe. Pushpivot pin through bushings and valve until pin end is flush with outside of pipe. Checkexhaust valve for freedom of movement.

32368

if valve is not positioned properly (long lip down}, it will restrict exhaust flow and fail to prevent water backing up into engine. Boat performance would be adversely affected, and engine may suffer water damage. 3. Install intermediate pipe following Hose and Pipe Replacement.

procedure under Exhaust

Engine Coupler Replacement- SX Models 32369

Removal 1. Removeengine from boat. if coupler is being replaced due to coupler failure (rubber hub of splined hub), check engine alignment after installing new coupler. See Drive Removaland Instal|ation section of the Drive Unit/Transom Shield WorkshopManual. 2. Disconnect all wires, lines and connectors from bellhousing. I~] [~ 3. Remove screws securing slide cover out.

bellhousing

cover,

and 26034

3-42

19085 Englne/eng

[6~ 4. Pull drain hose out of bellhousing. [7~ 5. Unscrewbolts and nuts retaining bellhousing. Disconnect ground wires. Removepower steering cooler bracket. 6. Removebeilhousing from engine block. [3 7. Unscrew six nuts securing coupler and remove coupler from studs. 8. Removeold gasket from bellhousing surface thoroughly.

cover.

¯

v- -

Clean gasket 19842

Installation [9~ 1. Install coupler and secure with six Iocknuts. Use a suitable adaptor and tighten to 40-45 ft. Ibs. (54-61 N.m). EEl 2. Install beHhousing and attach power steering c, ooler. Tighten nuts and bolts to 32-40 ft. Ibs. (43-54 N-m). Attach ground wires and tighten nuts to 15-20 ft. Ibs. (20-27 N-m). 3. Push drain hose into bellhousing. 4. Apply Gasket Sealing Compoundto both sides bellhousing gasket and position it on cover.

of a new

[~ 5. Clean seven self-tapping screws with a wire brush. Install betJhousJngcover and screws. Tighten to 60-84 in. Ibs. (7-9 N-m). 6. Connectall wires, lines and connectors to bellhousing. 7. install enginein boat.

6712

6714

GeneralSpecifications- 4.3 GL, GS, andGi __ Type - No. of Cylinder ..................................... 90" - V-6 Bore and Stroke ..................... 4.00 x 3.480in, (101.6 x 88.39 mm) Piston Displacement ....................... 262CubicInches(4.3 liters) Cylinder Numbers - Front to Rear Starboard ................................................ 2-4-6 Port .................................................... 1-3-5 Firing Order ........................................... 1-6-5-4-3-2 CompressionRatio .......................................... 9.3:1 Water TemperatureControf ............................... Thermostat Thermostat Opens at ........................................ 160° F Alternator Belt Adjustment.............. 1,4"-1/2"flex (20- 25kg, 44- 55lbs) Full throttle operating range, GL...................... 4200 = 4600 RPM Full Throttle Operating Range,GS, Gi ...................... 4400 - 4800

GeneralSpecifications - 4.3 GL,GS,andGi * Type - No. of Cylinder ..................................... 90° - V-6 Bore and Stroke ..................... 4.00 x 3.480in, (101.6 x 88.39mm) Piston Displacement ....................... 262CubicInches(4.3 liters) Cylinder Numbers - Front to Rear Starboard ................................................ 2-4-6 Port .................................................... 1-3-5 Firing Order ........................................... 1-6-5-4-3-2 Compression Ratio .......................................... 9.4:1 Water TemperatureControl ............................... Thermostat Thermostat Opensat ........................................ 160° F Alternator Bett Adjustment.............. 1A"-1/£’flex (20- 25kg, 44- 55Ibs) 4200 - 4600 RPM Full throttle operating range, GL...................... Full Throttle Operating Range,GS, Gi ...................... 4400- 4800

GeneralSpecifications - 5.7 GL,Gi 90° - V-8 Type - No of Cylinders ..................................... Bore and Stroke .................... 4.000 x 3.480 in. (101.6 x 88.39mm) Piston Displacement ....................... 350Cubicinches(5.7 liters) Cylinder Numbers - Front to Rear 2-4-6-8 Starboard .............................................. 1-3-5-7 Port .................................................. Firing Order ........................................ 1-8-4-3-6-5-7-2 Compression Ratio .......................................... 9.3:1 Water TemperatureControl ............................... Thermostat Thermostat opens at ........................................ 160°F 1/4"-1/2" flex (20 25 kg, 44 55 Ibs) Alternator Belt Adjustment.............. 4200 4600 RPM Full Throttle Operating Range........................

_ _

EngineSpecifications Pistons: Production Clearance ............................................. Service .......................................................... Piston Rings, Compression: Production Groove Clearance Top .................................................. 2rid .................................................. Service ..................................................... Gap Top .................................................... 2nd .................................................... Service ..................................................... Oil Rings: Production Groove Clearance ..................................... Service .............................................................. Production Gap .................................................... Service .............................................................. Piston Pins: Diameter ....................................................... Production Clearance ............................................. Service ............................................................ Fit in Rod .............................................. Connecting Rods: Bearing Clearance, Production ...................................... Service .......................................................... Side Clearance .................................................... Crankshaft: End Play ......................................................... Main Journal Diameter No. 1 V-6 and V-8 ........................................ No 2, 3 V-6, No. 2, 3, 4 V=8 ................................. No 4 V-6, No. 5 V-8 ....................................... Taper, Production ................................................... Service ............................................................ Out-of-Round, Production ............................................. Service ............................................................ Main Bearing CJlearance, Production No. 1 V-6 and V-8 ........................................ No 2, 3 V-6, No. 2, 3, 4 V-8 ................................. No 4 V=8, No. 5 V-8 ....................................... Service No. 1 V-6 and V-8 ........................................ No 2, 3 V-6, No. 2, 3, 4 V-8 ................................. No 4 V-6, No. 5 V-8 ...................................... Crankpin Diameter ................................................ Taper Production ............................................ Service .............................................. Out-of-Round, Production ............................................. Service ...........................................................

Engine/eng

3-45

0.0007 - 0.0017 in. 0.0027 in. Max. 0.0012 - 0.0032 in. 0.0012 - 0.0032 in. + 0.001 in. 0.010 - 0.020 in. 0.010 - 0.025 in. + 0.010 in. 0.002 - 0.007 in. Max, + 0.001 in. 0.015 - 0.055 in. + 0,010 in. 0.9270 - 0.9273 in. 0.00025= 0.00035in. 0.001 in. Max. 0.008 - 0~.0016in. Interference 0.0013 - 0.0035 in, 0.0030 in. Max. 0.008 - 0,014 in. 0.002 - 0.006 in. 2.4484- 2.4493 in. 2.4481 - 2.4490 in. 2.4479 - 2.4488 in. 0.0002 in. Max. 0.001 in. Max. 0.0002 in. Max. 0.001 in. Max. 0.0008 - 0.0020 in. 0.0011 - 0.0023 in. 0.0017 - 0.0032 in. 0.001 0.001 0.0025 2.0988

-

0.0015in. 0.0025in. 0.0035in. 2.0998in.

0.005 in. 0.001 in. 0.0005 in. 0.001 in.

Max. Max. Max. Max.

Engine Specifications - Continued Camsl-~ft: Camshaft EndPlay........................................... 0.004 - 0.012 in. (0,101 - 0,304 mm Camshaft Bearing Journal Diameter ........ 1.8682- 1.8692 in. (47,452 - 47,477 mm Camshaft Run-out .................................................................. 0.0015 in. (0,0381 mm LobeLift ................................................................... V-6 intake 0.234 in. (5,943 mm V-6 Exhaust 0.2576 in (0,527 mm V-8 intake 0.269 in (6,832 mm V-8 Exhaust 0.276 in (7,010 mm Valve System: Lifter Type..................................................................................................... Hydraulic Rocker ArmRatio................................................................................................ 1.5:1 Not Adjustable ValveLashV-6.................................................................................... Zero + One Turn ValveLashV-8.................................................................................. 45° ValveFaceAngle................................................................................................... °46 ValveSeatAngle................................................................................................... Valve Guide Clearance: IntakeandExhaust...................................... 0.001 - 0.0027 in (0,0254 - 0,0685 ram) +0.002 in (0,0508 mm) MaxServiceClearance,Exhaust............................................ +0.001 in (0,0254 mm) MaxServiceClearance,Intake .............................................. Valve Seat Width 1/32 to 1/16 in (O,7937 - 0,1587 ram) Intake.............................................................. 1/16 to 3/32 in (0,1587 - 0,2381 mm) Exhaust ........................................................... ValveSpringLength ................................................................... 2.03 in (51,562 mm) Valve Spring Pressure mb@in. (kg @mm}........................................... 76-84 @ 1.70 (34,5 - 38,1 @ 43,18) Ib @in. (kg @mm)............................................ 194-206 @ 1.25 (88-93.4 @ 31.75) EngineLubrication: Oil Pump Type...................................................................................................... Gear Crankcase Capacity - quarts (liters) 4 qts., 4.5 w/filter (3,78 lit., 4,26 w/filter) 4.3 GL,GS,Gi .......................................... 5 qts., 6 w/filter (4,73 lit., 5,68 w/filter) 5.7Gi.......................................................... 15-30 psi (1,055-2,109 kp/cm =} @ 800 RPM Oil Pressure,warmengine..................... 40-60 psi (2,812-4.218 kp/cm =) @ 2000 RPM Recommended Oil Grade: SG Service - GM Spec 6094M 32° F (0° C) andabove................................................................................... 0° F (-18° C) to 32° F (0° C) ................................................................. -0° F (-18°C)...............................................................................................

SAE 30 SAE 20W-20 SAE lOW

WerecommendDuraPlusTM Synthetic Motor Oil, which is specially formulated for heavy duty marine use and ideaRfor Volvo Pentaengines. It provides better anti-wear qualities, especially during long high speedoperation. In addition, it neutralizes acids causedin internal combustionengines, offers superior corrosion protection, and is formulated to offer better resistance to oxidation and high temperature sludge formation. Recommended Fuel............................................................

See General Information

Section

TorqueSpecifications- All Models The following specifications

are for screw sizes not shownotherwise:

SCREW SiZE No. 6 No. 10 No. 12 V4 sAs %

FT. LBS

IN. LBS.

N-m

2-3 3-4 5- 7 10- 12 18 - 20

7- 10 ;!5-35 35-45 60 - 80 1;!0- 140 2;!0 - 240

0,.8- 1 :3-4 ,4-5 7- 9 14- 16 2,4 - 27

Use a reliable torque wrench to tighten the parts listed to prevent straining or distorting the parts or possibly damagingthe threads. These specifications are for clean threads only. Dirty threads produce friction which prevents accurate measurement of tightness. It is important that these torque specifications be strictly observed. Overtightening to any extent maydamagethreads, thus preventing proper torque from being obtained, requiring replacement or repair of the damagedpart.

Balance Shaft Driven Gear Balance Shaft Retainer Camshaft Sprocket Camshaft thrust Plate V-6 Circulating Pump Coil Clamp Crankshaft Oil Seal Retainer Dipstick TubeFitting Distributor Clamp Flywheel Bellhousing Flywheel Cover Front Mount to Engine High Rise Elbow to Manifold Lift Bracket Oil Filter BypassValve Oil Pan (1/4 × 20) Oil Pan (5/16 × 18) Oil PumpCover Oil Seal Retainer Power Steering PumpBracket Rocker Arm V-6 Rocker Arm Cover Starter Motor Raw-water Pump Bracket Thermostat Housing Timing Chain Cover

~’ 15 +35 21 30 15-18 20 32-40 32-40 12-18 15-29 20 6-9 26-30 4O

120 105 7-10 135 60-84 80 165 135 90

30-36 30 12-16 80

°20 +35 14 28 11,g 41 0,7g-1,13 15,3 20-24 27 43-54 7-9 43-54 16-24 20-39 27 9 18,6 8-12 15,3 35-41 54 10 41-49 41 16-22 9

TorqueSpecifications - (Cont.) [ FT. LB$.~ (iN. LBS.

Camshaft Sprocket Connecting Rod Cap Crankshaft Oil Seal Retainer Exhaust Manifold Flame Arrestor Flare - Dipstick Tube Flywheel and Coupler Flywheel Belmhousing Front Mount Top Oil Pan (5/16 x 18) Oil Withdrawal Tube to Elbow Power Steering Bracket

21 45 20-26 15-18 40-45 32-40 100-120 15-18 13-15

Cylinder Head Step 1 Step 2 Step 3 Harmonic Balancer (7/16 x 20) High-Rise Elbow Front Mount intake Manifo0d Main Bearing Cap Outer Bolts on #2, #3, and #4 Caps All Other Bolts Oil Pump RemoteOil Filter Adaptor (to block)

135 30-40 165 -

25 45 65 55-62 12-18 60-75 30

-

7O 80 65 20-25

Balance Shaft Drive Gear Flame Arrestor Flywheel and Coupler Power Steering PumpBracket

12 10-15 13-15

Spark Plugs Oil Filter Oil Pan Drain Retainer Oil Pressure Sender Oil Pressure Sender Adaptor Water Temperature Sender

22

34 61 88 75-84 16-24 81-102 41 95 110 90 27-34

65-80 -

OneTurn 15-18 10-14 10-14 18-22

3-48

28 60 15,3 27-35 3,4-4,5 20-24 54-61 43-54 136-163 18,6 20-24 18-20

18 7-9 14-20 18-20

30 After Contact 20-24 14-19 14-19 24-30

Engine/eng

Section4 5.0 and 5.8 FL Table of Contents Circulating PumpReplacement........................... Core Plugs ........................................... Crankshaft Rear Oil Seal ............................... Cylinder Head .......................................... Diagnosis and Testing Camshaft Lobe Lift ................................... Compression Test ................................... PCVSystem .......................................... Engine Coupler Replacement ........................... Engine Specifications .................................. Exhaust (Flapper) Valve Replacement.................... Exhaust Hose and Intermediate Pipe Replacement......... Exhaust Manifold Replacement ........................... Front Cover and Timing Chain ........................... Front Engine Mounts ................................... Height Adjustment ................................... Front Oil Seal ......................................... High-Rise Exhaust Elbow Replacement ................... Intake Manifold ......................................... Oil Pan ............................................... Oil Pump............................................. Torque Specifications .................................. Valve Clearance Check ................................. Valve Lifter ........................................... Valve Rocker Arm and Cover ............................ Valve Spring, Retainer and Stem Seal .................... /~

Safety

4-6 4-23 4-18 4-9 4-24 4-25 4-26 4-32 4-36 4-31 4-30 4-5 4-12 4-27 4-29 4-14 4-29 4-3 4-15 4-16 4-34 4-21 4-22 4-19 4-11

Warnings

Beforeworkingon anypart of the engine,readthe sectioncalled Safetyat the endof this manual. Unlessinstructed otherwise, alwaysdisconnectthe battery cables from the battery beforeworkingon electrical system1o preventpossiblesparks or arcing in the enginecompartment. Beforestarting engineafter repair or maintenance procedures,alwaysmake sure enginecompartment is free of fuel vaporsto preventpossiblefire and explosion. When workingon an enginethat is runningor being cranked,use extreme care to avoidgetting hands,fingers or clothing caughtin the alternator, powersteering pump,raw-waterpumpandcirculating pumpbelts, pulleys andother movingparts.

i

Materials Required Cleaning somvent DuraPlus Synthetic Motor Oil Gasket Sealing Compound Loctite primer or equivalent Loctite or equivament Scotch-Grip Rubber Adhesive RTVSilicone Rubber Sealant

OTCTools Required T58L-101-APilot Bearing Puller T58P-6316-D Damper Remover T59L-100-BPilot Bearing Puller T61P-6019-B Cover Aligment Tool T65P-6701-AOil Seal Installer TTOL-6500-ALifter Puller TTOP-6049-A Valve Spring Compressor TTOP-6B070-A Seal Installer TTOP-6B070-B SeaJ Remover T71P-6513-B Hydraulic Lifter Compressor T74P-6666-A Plug Wire Remover "F77L-9533-B Slide HammerTool "F79=F-6316-A DamperhstaHer T82L-6701-AOil Seal Installer Order from: OTCDivision of SPXCorporation 655 Eisenhower Dr. Owatonna, Minnesota 55060 Phone: 1-800-533-0492 or 1-800-533-5338

Eng~,ne/eng

intake Manifold Removal [~ 1. Drain cooling system. Removenut (~, then remove flame arrestor cover. I[~ 2. Removethe second nut (~), then removehose © and flame arrestor (~. I~ 3. Removethermostat housing (~) on intake manifold. Disconnect fuel line (~ and fuel pumpvent hose at carburetor. 4. Disconnect spark plug wires at distributor I~ 5. Removedistributor assembly @.

34741

cap and coil.

assembly @. Removecoil

and bracket

6. Disconnect wiring harness at coil terminals, engine temperature sending unit, choke and other connections as necessary. 7. Disconnect throttle cable (~ at carburetor. Remove throttle cabJe bracket (~ from manifoJd. Disconnect PCV hose ® at :carburetor spacer.

34740

8. Removeattaching bolts, and removeintake manifold, deceleration valve, and carburetor as an assembly. if necessary to pry manifold awayfrom cylinder heads, do ,not damagegasket sealing surfaces. 9. Removeand discard intake manifold gaskets and seals. Cleaning Removeall gasket material from the machined surfaces of the !manifold. Cleantile manifold in a suitable solvent and dry it with compressedair. llnspection Ilnspect the manifold for cracks, damagedgasket surfaces, or other defects that wouldmakeit unfit for further service. Replace alJ studs that are stripped or otherwise damaged.Removeall filings and foreign matter that mayhave entered the manitfold as a result of repairs. Ilnstallation 1. Clean mating surfaces of intake manifold, cylinder heads, and cylinder block. Use a solvent such as Ford Spot Remover(B7A19521-A), Cleaning solvent or similar degreasing agent.

E ngine/eng

4-3

34738

[~ 2. Appaya 1/e in. diameter bead of silicone rubber sealer (~) (C3AZ-19562-A or B) in and along the joint, the full width of the cylinder block sear mounting surface (~) (four corners) as shown. EEl 3. install the cylinder head to manifold gaskets ©, and the front and rear intake manifold to cylinder block seals @. Apply a 1A8 in. bead of sealer (~) at the outer end of each intake manifo0d seal for the full width of the seal. [~ This sealer sets up within 15 minutes after application, so assemblyshould proceed promptly, 4. Carefully lower intake manifold into position. Whenintake manifold is in place, run finger around seal area to be sure seals are in place, if seals have shifted, removemanifold and reposition seals. [~] 5. Be sure intake manifold gaskets are properly aligned, then install attaching bolts. Tighten snugly to manifold, then tighten bolts in recommendedsequence to proper torque. Repeat torque sequence, tightening bolts again to original torque value. Because the center manifold bolts becomeloose, re-torque manifold bolts seasonally. DE] 6. install thermostat housing and adaptor assembly on intake manifold. Install distributor and hold downclamp.

% ® DR2215

[~E] 7. Connect PCVhose to carburetor spacer. E~ Z~ 8. Connect fuel line to carburetor. Tighten line nut securely. Instalm coil and bracket assemblyto intake manifold. EEl 9. Connect engine harness wiring to coi{, ature sender.

choke and temper-

EEl 10. Attach throttle cable bracket to manifold and throttle cabZe to carburetor and anchor block. DE] 31. Connect spark plug wires to distributor cap, and high tension lead to coil. Be sure plug wires are replaced in proper order to ensure correct firing order. See Ignition Systemsin the Electrical~Ignition SystemWorkshopManual. [~ Z~ 12. install flame arrestor and cover. Makesure engine compartmentis free of fuel vapors, Start engine and check for fuel leaks. Check and adjust ignition timing. Check engine for cooling leaks. EE] 13. After engine reaches normal operating temperature, retighten manifold bolts and nuts to proper torque in correct sequence.

Safety Related

4-4

DR2666 Englne/eng

34737

34736

34735

Exhaust Manifold Replacement Removal [~ 1. Loosen six hose damps ~ holding exhaust elbow (~).

exhaust hoses to

2. Lubricate lower hose and exhaust pipe with a soapy water solution, and slide hose downonto pipe. [=~ 3. Removeexhaust elbow from high-rise 4. Starboard manifold only, removeelectrical

hose.

34726

cable from J-clamp.

[~ 5. Removethe four screws ® securing high-rise Removethe elbow and discard the gasket.

elbow O.

6. Loosen clamp and pull water hose off front of manifold. 7. Pull spark plug leads off spark plugs. Mark plug wires to ensure correct firing order. [~ 8. Unscrew eight Iocknuts and hock washers holding manifold to mounting studs. Pull manifold off studs.

25927A

9. Removeand discard exhaust manifold gasket. Instal|ation [~ 1. Install a new exhaust manifold gasket. Gasket ports, must completely align with exhaust openings. [~ Gasket can be correctly installed in onny one position. If improperly installed, gasket will block off part of each exhaust port and/or block access to spark plugs. 25926

Engine/eng

4- 5

25924A

2. Slide manifold onto studs. Attach lock washers and tocknuts, and tighten Iocknuts to 20-26 ft. Ibs. (27-35 N-m). 3. Coat a new gasket with Gasket Sealing Compound and place it on manifold. Install high-rise enbow. Tighten elbow screws to 12-18 ft. ibs. (16-24 N-m). [~] 4. Attach water hose to nipple at front tighten clamp. 5. Starboard manifold only, secure electrical

of manifold and

cable in J-clamp.

6. Attach spark plug wires to plugs. Makesure firing correct.

order is

2592.3

[~] 7. Lubricate upper (large diameter) outside surface of exhaust elbow with a soapy water solution, and push elbow into high-rise hoseuntil it seats. [~ 8. Lubricate lower end of exhaust elbow and slide Bower hose up onto elbow. Position hose so that it equally covers elbow and exhaust pipe. Z~ [~ 9. Install the six hoseclampsand tighten themsecure|y. Runengine and check for exhaust leaks.

Circulating

15527

PumpReplacement

Removal 1. Drain all water from engine block. [’~ 2. Loosen the circulating pump pulley bolts, but don’t removethem at this time. Note, belt tension will keep the pump from turning while bolts are removed. 3. Release tension on the alternator belts, then remove them.

and power steering pump

15545

4. Unscrewthe pulley bolts, and slide the pulley offthe circulating pump hub. [~ 5. Removethe two power steering bracket bolts.

Safety Related

4-6

Engine/eng

15546

[3 6. Removebrace from alternator pump.

15547

25921

bracket to power st,eering

7. RemoveTorx head bolt ~) and spacer and remove power steering pump. [~ 8. Removealternator brace from circulating ing bolt and lock washer,

pumpby remov-

[~ 9. Loosen hose clamp, and pual large hose off circulating pump.

25920

[~ 10. Take out alternator bracket bolts. Removealternator and disconnect electrical leads at back of alternator. Set alternator aside. ~’2-~ 11. Removeall pump mounting boSts. Lightly strike pump with soft hammerto free it from the mounting gasket. T~ke off pump, then remove and discard gasket. installation 11. Thoroughly clean gasket surface on bmock.Coat both sides of a new gasket with Gasket Sealing Compoundand position it on block. Carefully align bolt homesand water passages.

15550

2. install circulating pump. Screw in all bolts except those that attach the alternator and power steering pump bre~ckets. Tighten bolts to 1:2-18 ft. Ibs. (17-24 N-m)o

15658

25920A

EEl 3. Push aarge water hose onto pumpinlet securely.

15529

and tighten clamp

I-2] 4. Place spacer and Torx head bolt behind rear power steering pump bracket and secure to block. Attach two power steering pump bracket screws and lock washers. EEl 5. Attach the alternator and alternator bracket to the circulating pumpwith screws, lock washers and flat washers. Tighten the screws to 18-20 ft. Ibs. (24-27 N.m). 25%21

6. Attach electrical leads to back of alternator. 7. Attach alternator brace to circulating tighten pivot bolt at this time.

pumpcover. Do not

EEl 8. Attach power steering pumpbrace to alternator with screw and lock washer.

bracket

EEl 9. Align the pulley and pumphub screw holes, then slide the pulley onto the pump. Install the screws and lock washers and tighten them to 14-20 ft. Ibs. (19-27 N-m). 10. Install the power steering pumpbelt and position it in the innermost pulley grooves. InstaJJ the aJternator belt in the next outer groove.

15528

The two belts are different lengths. The power steering pumpbelt is longer and goes on first. 11. Tension both belts as recommended;see General information section. Tighten all power steering and alternator bracket bolts securely. 12. Run engine and check for water leaks. 15527

4-8

Engine/eng

Cylinder Head Removal 1. Completelydrain cooling systemto ensureno water remainsin the intake manifold, cylinder heads,exhaustmanifolds, hosesor block. :2. Disconnect the spark plug leads at the plugs. Removethe exhaustmanifolds, then spark plugs. 3. Remove the upperand lower intake manifolds. SeeUpperintake Manifold Removalin the Fuel SystemService Manual.Seeintake Manifoldin this chapter.

DR4858

®

4. Removeany components, brackets or clamps that may be attachedto the front or rear of the cylinder heads.Notetheir posit;ion so that they canbe propedyreinstalled. 5. Remove the rocker armcovers. Discard the old gaskets. 6. Loosenthe rocker armbolts so that the rocker armsmaybe rotated. Remove the pushrods in sequence so they can be installed in their original positions.

-<

® DR5601

[8~ 7. 5.0 Liter Only: Remove and inspect cylinder headbolts. Retainstandardheadbolts (~; they can be reused. Discard"torque to yield" headbolts (~); replace themwith new"torque to yield" headbolts. Lift the headoff the block. Discardheadgasket. 8. 5.8 Uter Onb/: Remove the cylinder headattaching bolts andlift tihe headoff the block. Discardheadgasket. Installation F~’-R3 L ~_~.J1. Cleanthe cylinder head,intake manifold,rockerarm(’overs andcylinder block gasket surfaces. If the headwasremovedfor a cylinder headgasket replacement,checkflatness of the headand block gasket surfaces. Surface must not deviate morethan 0.003 in. (0,076 mm)inany 6 in. (152,4 mm)area, and .006 in. (0,152 ram)overall. 2. A specially treated compositiongasket is used. Do not apply sealer to a composition gasket.Position the newheadgasket over the alignment dowels.Place the headon the block and insert the attachingbolts.

Englne/eng

4-9

DR4859

[~ 3. Thecylinder headbolts are tightenedin two stepsfor air 5.8 liter engines,andin either twoor three steps(torqueto yield method} for the 5.0 liter engine dependingon which type headbolts are used.Followthe illustrated torque pattern, andtighten as follows: ,~WARN|NG:Donot reinstall totrlUe to ~eld headbolts. Torqueto yield headbolts mustbe replaced oncethey are removed. ¯ 5.0 Liter Engineswith torqueto yield bolts: Step1. 25-35ft. ab. (33,8 - 47,4 Nm) Step2. 45-55ft. Ub. (61,0 - 74,5 Nm) Step3. Turnall bolts in sequence additional ° ° 85 -95 (¼ turn} o 5.0 Uter Engineswith standardhex headbolts: Step 1. 55-65ft. lb. (74,6 - 88,2 Nm) Step 2. 65-72ft. lb. (88,2 - 97,6 Nm) e 5.8 Liter Engines: Step 1. 95-105ft. lb. (128,8 - 142,4 Nm) Step 2. 105-112ft. lb. (142,4- 151,9 Nm) 4. Cleanthe pushrods in solvent. Blowout the oil passagein the pushrods with air. Checkthe endsfor nicks, groves, roughnessor excessivevvear. Visually checkpushrods for run-out or with a dial indicator. Replacepushrod if run-out exceeds0.015 in. (0,381 mm)at any point. Do not attempt to straighten and reuse push rods. 5. Lubricate the rocker armendof pushrod with FordMultipurpose GreaseDOAZ-19584-AA or equivalent, and instalJ themin their originaJpositions.

DR2599

6. Lubricate the valve stem ends with Ford Multipurpose Grease DOAZ-19584-AA or equivalent. ~] 7. Lubricate the rocker arms and fulcrum seats with Ford Multipurpose GreaseDOAZ-19584-AA or equivament. Install the rocker armsfollowing the procedureunderValveRockerArminstallation. 8. Clean the rocker armcover gasket surfaces. Securenewgaskets in the coverswith gasketsealer to ensureproperhole aJignment.Install the covers; tighten the mountingscrewsto 36-60in. lb. (4-8 Nm). 9. Install the intake manifold.Seeintake Manifoldin this chapter. 10. Install any components, brackets, or clampsthat wereremoved. 11. Install spark plugs, and the exhaustmanifolds, then connect the spark plug ~eads.

4-10

Engineleng

Valve Spring, Retainer and StemSeal RemovaU Broken valve springs, or damagedvalve stem seals and retainers, may be replaced without removing the cylinder head, provided damageto the valve or valve seat has not occurred.

1. Remove rockerarmcover. 2. Removethe applicable spark plug and bring the piston to the top of the bore to prevent accidental loss of the valve into the cylinder.

DR4861

3. Removethe rocker arm fulcrum bolts, fulcrum seats, i’ocker arms and push rods from the applicable cylinder. 4. fnstall an air line with an adapter in the spark plug hole and apply air pressure to the cylinder. Failure of the air pressure to hold the vamvein the closed position is an indication of valve seat damage,and requires removal of the cylinder head. E3~ 5. Install the fulcrum bolt and position Valve Spring Compressor Tool TTOP-.6049-Aor equivalent as shown. Compressthe valve spring and removethe retainer locks, spring retainer, sleeve and valve spring. 6. Removeand discard the valve stem seal. ~ If air pressure has forced the piston to the bottom of the cylinder, any removal of air pressure will allow the valve "to fall into the cylinder. A rubber band, tape or string wrappedaround the end of the valve stem will prevent this condition and will still ~llow enoughtravel to check the valve. 7. Inspect the valve stem for damage.Rotate the valve and check 1:he stem tip for eccentric movementduring rotation. Movethe vane up and down through normal travel in the valve guide and check the stem for interference, if the valve has been damaged, it’ll be necessaryto removethe cylinder head, Installation 1. if the condition of the valve stemprovedsatisfactory, iub,ricate the valve stem with the recommendedengine oil Hold the valve in the closed positiion and apply air pressure within the cylinder. ~4-’-] 2. Install a newvalve stemseal on the valve guide. Seal must be bottomedon guide. Place the spring in position over the valve, and install the spring retainer and sleeve. Compressthe valve spring and install the spring retainer locks. Remove the compressor tool and fulcrum bolt.

DR4862

3. Lubricate the upper push rod ends with Ford Multi-Purpose Grease DOAZ-19584-AA or equivalent, and install the push rod. Apply the samegrease to the tip of the valve stem. 4. Apply Ford Multi-Purpose Grease DOAZ-19584-AAor equivalent to the rocker arms and fulcrum, install the rocker arms, fulcrum and fulcrum bolts. Tighten the bolts to 18-25 ft. lbs. (24-34 N-m). 5. Turn off the air and removethe air line and adapter. Install the spark plug and connect the plug wire. DR4863

6. Install the rocker arm cover using new gaskets; follow the procedure under Rocker Armand Cover Installation.

Front Cover and Timing Chain Removam 1. Refer to Citcu|ating PumpRemovalsection. Perform all steps except removal of the pump. Leave it attached to the front cover. [~] 2. Remove the crankshaft pulley. Unscrew the damper attaching bolt and washer. Attach DamperRemover T58P-6316-D or equivalent, and pull vibration damperoff crankshaft. 3. Removethe oil pan-to-cylinder block front cover attaching bolts. Use a thin-bladed knife to cut the oil pan gasket flush with the cylinder block face prior to separating the cover from the block. 4. Removethe cylinder front cover and circulating assembly. Discard the front cover gasket.

pumpas an

5. Checkthe timing chain deflection. If deflection exceeds0.500 in. (12,7 mm), replace the chain and sprockets.

4-12

Englne/eng

[2---] 6. Crank the engine until the timing markson the sprockets are positioned as shown. 7. Removethe camshaft sprocket cap screw, washers and fuel pumpeccentric. Slide both sprockets and the timing chain forward, and remove them as an assembly. installation 1. Position the sprockets and the timing chain on the camshaft. Be sure the timing markson the sprockets are positioned as shown.

DR4864

3r~ 2. Install the fuel pump eccentric, washers and camshaft sprocket cap screw. Tighten the sprocket cap screw to 40-45 ft. Ibs. (55-61 N.m). 3. Clean the cylinder front cover, oil pan and the cylinder block gasket surfaces. Clean the oil pan gasket surface where the oil pan and front cover fasten. Install a newoil seal following proceduresunder Front Oil Seal Removaland installation. 4. Lubricate the timing chain and sprockets with heavy engine oil.

DR4865

5. Coat the gasket surface of the oil pan with sealer. Cut and position the required newgasket on the oil pan and apply .’sealer at the corners. Install the pan sealer as required. Coat the gasket surfaces of the block and cover with Ford Perfect Seal Sealing CompoundB5A-199554-A (ESR-M18P2-A) or equivalent, and po+ sition a new gasket on the block. 6. Position the cylinder front cover on the cylinder block. Usecare wheninstalming the cover to avoid seal damageor possible gasket mislocation. DR4866

I-E] 7. Install the cylinder front cover-to-seal alignment using Front Coyer Aligner Tool T61P-6019-Bor equivalent. 8. It maybe necessary to force the cover downwardto sliightly compress the pan gasket. This operation can be facilitated by using a suitable tool at the front cover attaching hole locations. 9. Coat the threads of the attaching screws with Ford Perfect Seal Sealing CompoundB5A-19554-A (ESR-M18P2-A) or equivalent and install the screws. While pushing in on the alignment tool, tighten the oil pan-to=coverattaching screwsto 9-11 ft. Ibs. (13-14 N.m). Tighten the cover-to-cylinder block mounting screws to 12-18 ft. Ibs. (17-24 N-m). Removethe alignment tool. 10. Apply Ford Multi-Purpose Grease DOAZ-19584-AA or equivalent to the oil seal rubbing surface of the vibration damperinner hub to prevent damage to the seal and to the front of the crankshaft for damperinstallation.

E=~ine/eng

4-13

[~ 11. Line up the crankshaft vibration damper keywaywith the key on the crankshaft, tnstali the vibration damperon the crankshaft using Damper Remover/Replacer Tool T79T-6316-A or equivalent. Install the cap screw and washer. Tighten the screw to 70-90 ft. Ibs. (95-122 N-m). install the crankshaft pulley, 12. Completethe remainingsteps under Circulating Pumpinstallation. 13. Operate the engine at a fast idle to bring the engine up to operation temperature. Checkand adjust ignition timing to specifications in Section 6, ElectricaUignition Workshop Manualunder Distributor, Finish Timing.

DRY67

Front Oil Seal Remova| 1. Removethe crankshaft pulley from the vibration damper. Removethe damper attaching screw and washer, install the puller on the crankshaft vibration damperand removethe vibration damper. 2. Place the Front Cover Seal Remover TTOP-6B070-Bor equivalent onto the front cover plate over the front seal as shown. Tighten the two through-bolts to force the seal puller under the seal flange.

DRd868

3. Alternately tighten the four puller bolts one-half turn at a time as shownto pull the oil seal from the front cover. installation EEl 1. coat a new front cover pUate oil seal with Ford MultiPurpose Grease DOAZ-19584-AA or equivalent. Place the front oil seal onto Front Cover Seal Replacer "F70P-6B070-Aor equivalent. Place the sleeve and seal onto the end of the crankshaft and push it toward the engine until the seal starts into the front cover.

DR4869

DE] 2. Place the installation screw, washer and nut onto the end of the crankshaft. Thread the nut against the washerand installer sleeve to force the seal into the front cover plate. Removethe installation tool from the crankshaft. 3. Apply Ford Multi-Purpose Grease DOAZ-19584-AAor equivalent to the oil seal rubbing surface of the vibration damperinner hub to prevent damageto the seal. Apply a white lead and oil mixture to the front of the crankshaft for damperinstallation, 4, Line up the crankshaft vibration damperkeywaywith the key on the crankshaft. Install the vibration damperon the crankshaft. install the cap screw and washer. Tighten the screw to 70-90 ft. Ibs, (95-122 N-m). install the crank pulley. Makesure the pulley bottomed on the damper pilot.

4-14

Englne/eng

Oil Pan Removal 1. Removeengine from boat following procedures in Engine Removal and Installation section found elsewherein this workshop manual. 2. Drain the crankcase.Unscrewthe dipstick tube. ~. Remove the oil pan attaching bolts and removethe pan braces and pan. 4. Refer to cleaning and inspection procedures.Checkthe gasket surface for damage causedby overtightenedbolts. Straighten the surface as requiredto restore original flatness. Cleaning Scrapeany dirt or metal particles from inside of pan. Scrape all old gasketmaterial from the gasketsurface. Washpanin a solvent and dry it thoroughly. inspection Checkthe panfor (:racks, holes, damaged drain plug threads, or damaged gasket surface. Inspect for damage (unevensurface) at the bolt holes caused overtorquing mountingbolts. Straighten surfaces as req~jired. Repair any damage,or replace the pan if repairs cannot be made satisfactorily. installation E4---i 1. Cleanthe gasket surfacesof block andoil pan. Coatthe block surface andoil pangasketsurfacewith oil-resistant sealer. Position oil pangasketon cylinder block. E E] 2. Holdthe oil panin place againstblock andplacepan]brace against pan. Install a bolt finger tight on eachside of oil panto hold it in place, then install the remainingbolts. Tightenthe bolts from the center outwardin eachdirection. Tighten ¼-20bolts to 9-11ft. Ibs. (13-14N-m).Tighten¥18-18bolts to 9-11ft. Ibs. (13-14 N-m). ~5-~ 3. Install dipstick tube fitting to pan; leave screwloose. Orient fitting andattach dipstick tube. Thentighten both fitting screwandflare nut to 15-18ft. Ibs. (20-24N-m).

DR2673

4. Fill engine to proper level with recommended engine oil. 5. install engineinto boat following proceduresin EngineRemoval andInstallation section. Start engineandcheckfor leaks;.

31576

Oil Pump Removal 1. Removeengine from boat by following Removaland installation section.

procedures in Engine

2. Removethe oil pan and related parts following the procedure under Oil Par= Removal. [~] 3. Removeoil pump inlet

tube and screen assembly. DR4591

DE] 4. Unscrew oil pump mounting screws. Remove pump and intermediate driveshaft. Disassembly 1. Removethe four screws and washers securing the oil cover to the oil pump, then oil pumpcover.

pump

2. Removeoil pumpouter rotor and rotor shaft assembly from the oil pump housing. 3. Removethe cotter pin that secures the relief valve plug in the oil pump housing. To remove the plug, drill a small hole and insert a self-tapping screwin the relief valve pUug. Use pliers to removeplug from oil pumphousing. Use care to prevent the loss of the relief valve spring. 4. Removespring and relief

DR4590

valve from oil pumphousing.

Cleaning Washall parts in solvent and dry them thoroughly with compressed air. Use a brush to clean the inside of the pumphousing and the pressure relief valve chamber. Ensure all dirt and metal particles are removed. inspection 1. Refer to Specifications for clearances and service limits. 2. Check the inside of the pumphousing and the outer race and rotor for damageor excessive wear. 3. Check the mating surface of the pumpcover for wear. If the cover mating surface is worn, scored or grooved, replace the cover, 32364

~] 4. Rest rotor assembly on flat surface. Measuretip clearance with a feeler gauge. Tip clearance must not exceed 0.004 in. (0,10 mm).

[~ 5. With the rotor assembly installed in the housing, measure the outer race to housing clearance (~). Your feeler gauge reading must be 0.001-0.013 in. (0,03-0,33 ram).

4-16

DR1840 CobrEng/eng

E5-~[ 6. Place a straight edge ~ over the rotor assemblyarid the housing. Measurethe cmearance(rotor end play) ©, between the straight edge and the rotor and outer race. Your reading must be 0.001-0.005in. (0,03-0,13 ram). 7. Checkthe driveshaft to housing bearing clearance by measuring the O.D. of the shaft and I.D. of the housing bearing. Correct c~earanceis 0.0015=0.0029in. (0,04-0,07 mm). 8. ff the pumpfails either Step 4, 5, or 7, replace the oil pump assembly. The outer race, shaft and rotor are repnaceabie only as an assembly. 9 Inspect the relief valve spring for a collapsed or worncondition. Checkthe relief valve spring tension. ¯ 5.0 FL Models: 1.74in. {44,2 mmllength with a 10.6-12.2 lb. (4,80-5,53 kg) load. e 5.8 FL Models: 2.49 in. (63,2 mm)length with a 18.2.-20.2 rb. (8,25-9,16 kg) load. ff the spring tension is not within specifications, and/or spring is worn or damaged, replace the spring. Check the relief valve piston for scores and free operation in bore. ~ot-~ The internal componentsof the oil pumpare not serviced. If any component is out of specifications, the pumpassembly must be replaced. Assembly 1. Instal[ relief vamve, spring and renief valve pUugin oil pump housing. Press plug inward until it seats, then install the cotter pin. 2. Install outer rotor and rotor shaft in housing. Be sure that identification markon outer rotor is on the sameside as identification mark on inner rotor. Fill the housing with engine oil for priming purposes. r~ in. 3. Install the cover plate and tighten the four screwsto 72-1z.0 Ibs. (8-18 Nora).

[n,sta|lation 1. Primeoil pumpby filling pumpinlet port with engine oil. Rotate pumpshaft to distribute oil within pumpbody. 2. Position intermediate driveshaft into distributor socket. With seat firmly seated in distributor socket, the stop on the shaft should touch roof of crankcase. Removeshaft and position stop as necessary.

Englne/eng

4-17

© DR1841

[~ ~ 3. With stop properly positioned, insert intermediate driveshaft ~) into oil pump.install pumpand shaft as an assembly. Donot attemptto forcepump into positionif it will not seat readily. The drive hex maybe misaligned with the distributor shaft. Rotate intermediate driveshaft to align. Tighten oil pump mountingscrews(~ to 22-32ft. lbs. (30-43N-m). EEl 4. Cleanand install oil pumpinlet tube and screenassembly using a newgasket. Tighten mountingscrews© to 10-15ft. Ibs. (14-20N.m). Attach oil pumptube to engineblock andtighten nut (~) to 22-32ft. Ibs. (30-43N.m).

1 DR4590

5. InstalJ oiU pan and related parts as outlined under Oil Pan Installation.

Crankshaft Rear Oil Seal All models have a one piece crankshaft rear oil seal. This completeseal is replaced without removingcrankshaft. Removal 1. Removeengine from boat by following procedures in Engine Removaland instal|ation section.

DR4591

2. Remove starter motor. 3. Remove flywheel housing, coupling, flywheel and cover.

#

FRONTOF ENGINE

4. Usinga sharp awl, punchone hole into the seal metal surface betweenthe lip and engine block. 5. Screwin the threaded end of Slide Hammer Tool T77L-9533-B or equivalent. Use the slide hammerto removethe seal. Use caution to avoid scratching or damagingthe oil seal surface. Rnstallation 1. Lubricate newseal with engineoil. r~ 2.5.0 FLModels:Position oil seal with seal lip facing forward on rear Oil Seal Installer T82L-6701-A or equivalent. Position seal and tool on rear of the engine. Alternate bolt tightening to properly seat seal. Therear face of seal mustbe within 0.005in. (0,127 ram)of rear face of block. ~] 5.8 FL Models: Start seal with seal lip facing forward and install it with the rear Oil Seal Replacertool T65P-6701-A or equivalent. Keeptool straight with centerline of crankshaft and install seal until tool contactscylinder block surface.

DR1860

FRONTOF ENGINE

4-18

DR2513 Engine/eng

E~ Removethe tool and inspect the seal to ensure it was not damagedduring installation. 3. Install

flywheel cover, flywheel, coupling and housing.

4. install starter motor. 5. mnstall engine into boat following procedures in Engine Removal and Instal|ation section.

Valve Rocker Arm and Cover Removal 1. Disconnect spark plug wires from spark plugs by gra=~ping, twisting and pulling molded cap only, using Spark Plug Wire Remover"I-74P-6666-A or equivalent. 21. Removethe e×haust manifold. 3. Removethe valve rocker arm cover(s). L~ 4. Removevalve rocker arm bolt (E), fulcrum ~), rocker arm and fulcrum guide (~. Inspection - Rocker Arm ~1: the pad at valve end of rocker armhas a groovedradius, replace rocker arm. Do not attempt to true this surface by grinding. inspection - PushRod Checkends of push rods for nicks, grooves, roughness or excessive wear. The push rods can be visually checkedfor straightness while they are installed in the engine by rotating them with the valve closed. They also can be checked with a dial indicator for a maximum runout of 0.015 in. (0,38 ram). if the push rod is visibly bent, should be replaced. Installation 1. Apply Ford Multi-Purpose Grease DOAZ-19584=AA or equivalent to the top of the valve stems, the rocker arm and fulcrum seats, and upper end of push rods.

Engine/eng

4=19

i Notej Thefollowingprocedure will placethe lifter on a flat of the camshaft,not on a portionof the lobe to allow easyinstallation of the rocker arms. E~] 2. Position No. 1 piston on TDCat the end of compression stroke, Position @, and install rocker arm, fulcrum, fulcrum guide and bolt on the following valves: ¯ No. 1 Intake, ® No. 4 Intake, o No. 8 Intake,

No. 1 Exhaust No. 3 Exhaust No. 7 Exhaust

DR1845

E~ 3. Rotate crankshaft to Position ®, 180° from TDC@, and install rocker arm, fulcrum, fulcrum guide and bolt on the following valves:

~) TDC 180° from (~) @ 270° from (~)

® No. 3 Intake, No. 2 Exhaust ¯ No. 7 Intake, No. 6 Exhaust E~ 4. Rotate crankshaft to Position ©, 270° from Position @, and install rocker arm, fulcrum, and bolt on the following valves: o No. 2 Intake, ® No. 5 Intake, o No. 6 Intake,

No. 4 Exhaust No. 5 Exhaust No. 8 Exhaust

5. Besure that the fulcrumbaseis insertedin its slot on the cynintier headbefore tightening the fulcrumbolts. Tighten fulcrum bolt to 18-25 ft. Ibs. (24-34 N.m). Checkvalve clearance following procedures under Valve Clearance Checking Procedure. 6. Cleanandinspect gasket surfaces of engineblock andvalve cover(s). Inspect valve cover gasket sealing surface(s) for damageand distortion due to overtighting of bolts. Place a newgasket in cover(s), making sure that tabs of gasket engagenotches provided in cover(s). 7. Position cover(s) on cylinder head gasket surface(s). Make gasket seats evenly all aroundhead. Install bolts. Thecover is tightenedin two steps. Tighten bolts to 36-60 in. Ibs. (4--6 N-m). Wait two minutes, then tighten bolts to the samespecifications. If the starboard cover was removed,install PCVvalve. 8. Install exhaust manifold. Connectspark plug wires. Start engine and checkfor leaks.

4-20

Engine/eng

VamveClearance Check Thevalve arrangement is on the port bankis E-I-E-I-E-I-E-I andon the starboardbankis I-E-I-Eq-E-I-E. Valvestemto valve rocker armclearanceshouldbe within specifications with the hydraulic lifter completelycollapsed.Repeated’valve reconditioningoperations(valve and/orvalve seat refacing) or valve seat recessionwearcausedby (extendeduse) will decreasethe clearanceto the point that, if not compensated for, the hydrauficvalvelifter wilt ceaseto function andthe valvewill be heldopen. iNote ’ Theuseof positive stop rockerarmbolts eliminatesthe need to adjust the valveclearance.However, to obtain the specifiecl valve clearance,it is importantthat all vanvecomponents be in a serviceable conditionandinstalled andtightenedproperly.

DR1846

To determinewhethernewservice parts are necessary,makethe following check: ~.~ 1. Remove the PURPLE wire from the "1" terminal of the starter assist solenoidso the enginedoesnot start, install an auxiliary starter switch. Crankthe enginewith the ignition switchOFFun= till the No. 1 piston is on TDCafter the compression stroke. E2-’] 2. Withthe crankshaftin the positions designatedin Steps2, 3 and4, position the Hydraulic Lifter Compressor Tool T71P-6513-B @ or equivalenton the rocker arm.Slowtyapply pressureto bleed down the hydrauliclifter until the plungeris completelybottomed.Holdthe lifter in this position andcheckthe available clearancebetween the rocker armandthe valve stemtip with a feeler gauge®. 3. With the No. 1 piston on TDCat the endof the compression stroke as shownin Position @,checkthe following valves: e No. 1 Intake, No. 1 Exhaust ® No. 4. Intake, No. 3 Exhaust ® No. 8 Intake, No. 7 Exhaust E’3~ 4. After checkingthe spacingon thesevalves, rotate the crankshaft to Position®, 180° fromTDC@,then checkthe following valves: ¯ No. 3 Intake, No. 2 Exhaust ® No. 7’ Intake, No. 6 Exhaust

E,~;~Jn~o,~ ~ SafetyRelated

4-21

DR1845

TDC ~) 18;0° from @ 270° from ~)

E~5. After checkingspacingon these valves, rotate the crankshaft to Position @,270° from Position @;andcheckthe following valves: e No. 2 Intake, No. 4 Exhaust e No. 5 Intake, No. 5 Exhaust e No. 6 Intake, No. 8 Exhaust ClearanceSpecifications: 5.0 FL Models Allowable: 0.071-0.193in. (1,8-4,9 mm) Desirable: 0.096--0.165in. 2,4-4,2 mm) 5.8 FL Models Allowable: 0.098-0.198in (2,5-5,0 mm) Desirable:0.123--0.173in. (3,1-4,4 mm) Valve Lifter Thefollowing procedureis applicable for removingoneor all of the valvelifters. Beforereplacinga hydraulicvalvelifter for noisyoperation, be sure the noise is not causedby impropervatve clearanceor by wornrocker armsand/or pushrods. Dirt, gumor varnishdepositsandair bubblesin the lubricating oil can causehydraulicvalvelifter failure or malfunction. Dirt, gumandvarnish can keepa checkvalve from seating andcause a loss of hydraulicpressure.Anopenvalvedisc will causethe plunger to forceoil backinto valvelifter reservoirduringtimepushrod is being lifted to forcevalvefromits seat. Air bubblesin the lubricating systemcanbe causedby too high or too low an oil level. Air mayalso be drawninto the lubricating system throughan openingin a damaged oil pick-uptube. Air in an oil lifter cancausea loss of pressureto lifter. RemovaU 1. Remove intake manifoldandrelated parts following procedures under Intake Manifold. 2. Remove the valve rocker armcovers. Loosenthe rocker armbolts andturn rocker armsto oneside. 3. Remove the pushrods in sequence so they canbe installed in their original positions. 4. UsingHydraulic TappetPurler T70L-6500-A or equivalent, remove lifters andplacethemin a rackso that they canby installed in their original bores.

DR1845

~) TDC ® 180° from~) @ 270° from(~)

Cleaning Thoroughly clean all the parts in cleaning solvent and wipe them with a clean, lint-free cloth. inspection inspect the parts and discard the entire lifter assemblyif any part shows pitting, scoring, galling or evidence of non-rotation. Replace entire assemblyif plunger is not free in the body. Checkfor freeness of operation by pressing downon the push rod ,cup. Thelifters can also be checkedwith a hydraulic tester to test leak-downrate. Follow tester manufacturer’s instructions ’to perform test. ilnstallation 1. Clean outside of valve lifters. Lifters and bores are to be lubricated with specified engine oil before instaJlation, install lifters in their original bores. Checkany newlifter for free fit in bore to which it has been installed. :2. Apply Ford Multi-Purpose Grease DOAZ-19584-AAor equivalent to valve stem tips and push rod ends. install push rods in original positions,, 3. Lubricate rocker arms and fulcrum seats with Ford MultiPurpose Grease DOAZ-19584-AA. 4. Position the rocker arms over the push rods and tighten the bolts following the procedure under Valve Rocker Arm installation. Adjust valve clearance following procedure under Valve Clearance Check, !5. install rocker arm covers following Arm and Cover installation.

procedure under Rocker

6. Install intake manifold and related parts following the procedures under intake Manifold.

Core Plugs Removal To removea large core plug, drill a I/2 in. (12,7 ram) hole in center of plug and remove with an Clutch Pilot Bearing Puller Tool T59L-100-Band T58L-101-Aor pry it out with a large drift punch. Ona small core plug, drill a 1~ in. (6,37 ram) hole in center of plug and pry it out with a small pin punch. Clean and inspect plug bore. Prior to installing a core plug, plug bore should be inspected for any damagethat ’would interfere with proper sealing of plug. if bore is damaged ill will be necessaryto true surface by boring for the next specified oversize plug. Oversize (OS) plugs are identified by OSstampedin fiat located on the cup side of plug.

Lightly coat plug and/or bore with an oil resistant (oil galley) water-resistant (cooling jacket} sealer, and install it following procedure for cup-type or expansion-type below: Installation - Cup-Type [~ Cup-type core plugs (~) are installed with flanged edge outward. The maximumdiameter of this plug is located at outer edge of flange. The flange on cup-type plugs flare outward with largest diameter at outer (sealing) edge (E). It is imperative to push plug into machinedbore by using a properly designed tool. Under no circumstances is plug to be driven into bore using a tool that contacts flange. This method will damagethe sealing edge and will result in leakage and/or plug blow out.

DR1847

The flanged (trailing) edge must be below chamfered edge bore to effectively seamplugged bore. If core plug replacing tool has a depth seating surface, do not seat tool against a non-machined(casting) surface. Installation

- Expansion-Type

Expansion-type core plugs ~ are instalJed with flanged edge inward. The maximumdiameter of this plug is located at base of flange with flange (~ flaring inward. it is imperative to pushor drive plug into machinedbore using a properly designed tool, Under no circumstances is plug to be driven using a tool that contacts crowned portion of plug. This method will expand plug prior to installation and may damage plug and/or plug bore. Wheninstalling plug, the trailing (maximumdiameter) must below chamfered edge of bore to effectively seal bore. if core replacing tool has a depth seating surface, do not seat tool against a non-machined(casting) surface.

Diagnosis and Testing CamshaftLobe Lift Checklift of each lobe in consecutive order, and makea note of the readings. 1. Removevalve rocker arm Cover. 2. Remove valve rocker arm. Install a solid, tappet-type push rod in push rod bore of camshaft lobe to be checked, or use the adapter for ball end push rods.

DR1848

[3-~] 3. Makesure push rod ® is seated against camshaft lobe. Install a dial indicator so that actuating point ® of indicator is in push rod socket (or the indicator baln socket adapter is on end of the push rod) and in same plane as push rod movement. 4. Removespark plugs. !5. Connectan auxiliary starter switch in starting circuit, Crank engine with ignition switch OFF.Bumpcrankshaft over until lifter is on basecircle of camshaftlobe. At this point, pushrod willl be in its lowest position. 6, Zero dial indicator. Continue to rotate crankshaft slowly until push rod is in fully raised position. 7. Comparetotal lift tions:

recorded on dial indicator with specifica-

5.0 FL Models: Intake: 0.260 in. (6,6 ram) Exhaust: 0.278 in. (7,1 ram) 5.8 FL Models: intake: 0.278 in. (7,1 ram) I’xhaust: 0.283 in. (7,2 mm) MaximumAllowable Loss: 0.005 in. (0,13 ram) 8. To check accuracy of original indicator reading, continue to rotate crankshaft until indicator reads ZERO.if lift on any lobe is below specified wear limits, camshaft and valve lifters operating on the worn lobe(s) must be replaced as well as any lifter showing pitting or having a contact face worn flat or concave. 9. Remove dial indicator and auxiliary starter switch. Install rocker arm. NOTE:Do not rotate crankshaft until hydraulic lifters have had a chance to bleed down. To do otherwise may cause serious valve damage.Manually bleeding downlifters will reduce waiting time. 10. Install the valve rocker arm cover. 11. install spark plugs. CompressionTest: ~ 1. Be sure crankcase oil is at proper level and of correct viscosity. Makesure that battery is properly charged. Operate engine for a minimumof 30 minutes at 1200 RPM,or until engine is at normal operating temperature. Turn ignition switch off; disconnect B+ lead at ignition coil positive (+) terminal:, then removeall spark plugs. :2. Set throttle plates at wide-openthrottle position. :3. Install

a compressiongaugein No. 1 cylinder.

Engineleng

~ Safety

Related

4-25

DR1849

4. Install an auxiliary starter switch in starting circuit. Using auxiliary starter switch, crank engine (with ignition switch OFF) at least five compression strokes and record highest reading. Note approximate number of compression strokes required to obtain highest reading. 5. Repeat test on each cylinder. Crank engine same number of compression strokes as was required to obtain highest reading on No. 1 cylinder.

The indicated compression pressures are considered normal if mowestreading cylinder is within 75%of the highest. Refer to the following exampne: Highest Reading: 140 PSI (6703 kPa) 75%: 105 PSi (5027 kPa) Jn this example, any cylinder reading less than 105 PSi (5027 kPa) indicates an improperly seated valve, or worn or broken piston rings. If one or more cylinders read tow, squirt approximately one tablespoon of engine oil on top of the pistons in low reading cyJinders. Repeat compressionpressure check on these cylinders. 1. If compressionimproves considerably, piston rings are at fault. 2. If compressiondoes not improve, valves are sticking or seating poorly or valve guides are leaking. 3. if two adjacent cylinders indicate low compression pressures and squirting oil on pistons does not increase compression, the cause may be a cylinder head gasket leak between cylinders. Engine oil and/or coolant in the cylinders couJd result from this problem.

Positive Closed-TypeVentilation System A maffunctioning closed crankcase ventilation system may be indicated by hoping or rough engine idle. Do not attempt to compensatefor this idle condition by disconnecting the crankcase ventilation system and making carburetor adjustments. The removalof the crankcaseventilation system from the engine will adversely affect fuel economy and engine ventilation with resultant shortening of engine life. To determine whether loping or rough idle condition is caused by a malfunctioning crankcase ventilation system, perform the following tests.

Safety Related

4-26

Engine/eng

1. Remove PCVvalve from its mounting, but leave vacuuminlet side connectedto hose. If the valve is functioning properly and riot plugged,a hissing noise will be heardas air passesthrough valve. A strong vacuum will be felt whena finger is placed over valve inlet. Checkfor vacuumleaks in hose line and at all connections. 2. Reinstall PCVvalve, then removecrankcaseair inlet hose at flame arrestor connection. Loosely hold a small piece of stiff paper (such as a 3 x 5 memo card or parts tag card) over opening at end of inlet hose. After a minute or so, (to allow crankcase pressure to lower) the piece of paper should be suckedagainst hoseopeningwith a noticeable force. I1l£II

I11 ill

I I ill’l

(i]i~

lilt!¯

RemovePCVvalve from its mounting and shake it. A metaNic c.licking noise should be heard, indicating that valve parts are free, andnot sticking. If ventilation systempassesthese two tests, it can be considered functionally OK,andno further serviceis required.If it fails either test, replace PCVvalve andrepeat EngineIdling Test. If systemstill doesnot passtest, clean ventilation systemhoses and all passagesto induction systemin accordancewith ,established procedures. Servicing PCVValve Donot attempt to clean crankcase ventilation regulatorv~dve,it should be replaced. Clean crankcaseventilation systemconnection(s) on intake manifoldby probingwith a flexible wire or bottle tirush. Clean hoses, tubes and associated hardwarewith a lowvolatility, petroleum-basesolvent and dry with compressed air. Front

Engine Mounts

31588

1

Removal [~ ~ 1. Prior to removing a front mount, measuredistance betweenlarge washer(~) and fiat ® on upper mount bracket. Recordthis dimensionso mountcan be correctly reassembled. [2~ 2. Removethe top nut and washersfrom the mount. [3 3. Removethe two lag screws © and washers securing the mount.

E~ine/e~

4-27

31582

31580

~4. Lift enginewith 1500lb. (680 kg) minimum capacity hoist to allow remova|of front mounL [~ 5. Remove two mountbracket-to-block screws and lock washers @and removebracket. Disassembly [~ Hold mount bolt with a socket, and remove the two nuts and disassemMe mount.

31578

Assembly E~ Place small washer® on the mountbott and insert bolt up through mount. Install large washer® and secure with nut @. Torqueto 60--75ft. Ibs. (81-102N.m). Installation [~ Fully seat front enginemountadjusting bolts into the front engine mount ®.

DR4558

~CAUTION Bolt hole @is usedfor 5=8liter blocks only, bolt hole O is for the 5.0 liter blocks only. Theenginewill be damaged if these positions are usedincorrectly. ; Notel The headof support screw and mating contact point on block mustbe free of paint. E~] 2. Sprayboth mountbracket-to-blockscrewswith Loctite primer or equivalent and allow to air dry. ApplyLoctite or equivalent to both screws. Attach bracket to engine with two screws and washers. Tightenscrewsto 32-40ft. Ibs. (43-54N.m).

11983

E~ 3. Place a 0.005 in. (0.13 mm)feefer gaugebetweenthe engine block and the engine mountadjusting bolt. Adjust the engine mountadjustingbolt in or out until a resistanceis felt on the feeler gauge. 4. Markthe engine mountadjusting bolt head. Back the engine mountadjustingbolt out exactly onehalf (1/2) turn. [~ 4. Install upper inner nut and washer® on mountassembly andplace bolt into bracket, then install top nut andwashers@.

DR4529A

5. Set height adjustment, refer to HeightAdjustment.

SafetyRelated

4-28

31577 Engine/eng

Height Adjustment 1. Lift enginewith a hoist capableof lifting at least 1500lb. (580 kg). Position engine at desired height. [6~ 2. To change engine height, tighten or loosen nuts ~ and @ as required. [6~ 3. After setting mount position, turn nut @up against underside of engine bracket and hold nut with a wrench. Tiighten top nut ~) to 50-70 ft. Ibs. (68-95 N-m). 31581

Any large adjustments to engine height should be followed by a check of engine alignment. Failure to check alignment could result in rapid engine coupler failure.

High-Rise Exhaust Elbow Replacement Removal EEl 1. Loosen two clamps securing upper hose. Lubricate inside of hose with a soapy water solution. EEl 2. Removefour screws, flat washers and lock washers mounting high=rise elbow. Use a soft hammerto free the elbow from the manifold. Use a twisting motion to pull high-rise from hose= Removeand discard the manifold gasket.

34723

Installation [~ 1. Thoroughly clean manifold gasket surface @. AppBy Gasket Sealing Compoundto both sides of a new gasket and place it on the exhaust manifold. [~ 2. Lubricate the inside of the exhaust hose with a soapy water solution. Insert the high-rise into the hose with a twisting motion, and push it into hoseas far as it will go.

34722

3. Position high-rise on manifold, install four screws, flat washers and lock washers. Tighten screws to 12-18 ft. ibs. (16-24 hi-m). 4. Slide clampsup onto hose and position them in the two surface channels. Tighten clamps securely.

34721

2601O

34725

Exhaust Hose and intermediate Pipe Replacement Removal [~ 1. Loosen four clamps ~ attaching c~ampsoff the hose.

lower hose, and slide

[~ 2. Lubricate inside of hose, top and bottom, with a soapy water solution, and slide hose downonto exhaust pipe. 34724

[~ 3. Loosen all clamps on upper hose. Removeintermediate pipe (~) with a twisting motion. ~] 4. Slide upper hose off high-rise elbow. DE] 5. Slide lower hose off exhaust Y-pipe. |nsta|lation [~ ~ Both the upper and lower hoses have a step in the inside diameter that must face the intermediate pipe. [~ 1. Lubricate inside diameter of lower hose with a soapy water solution. Slide it all the way onto the exhaust Y-pipe.

26025

[~ 2. Place four clamps on upper hose. Push hose all the way onto high-rise elbow. Position c~ampsin channels at top of hose, and tighten clamps securely. ~] 3. Lubricate inside of upper hose. With a twisting motion, insert intermediate pipe ® all the way into the upper hose and position it as shown. Do not attach the hose clamps at this time. 32366

4-30

2602,$ CobrEng/eng

Exhaust (Flapper) Valve ReplacementSX Models L~ 4. Slide lower hose up until it equally overlaps the intermediate and exhaust pipes. ET~ 5. Slide two clamps (~) onto upper hose. Slide four remaining clamps (~ onto lower hose. Position clamps in channels and tighten securely. Removal 6373

1. The exhaust valves are at the upper ends of the exhaust pipes. Removeadaptor pipes and lower exhaust hoses. ~.~ 2. Using a small drift or punch(~), push the exhaust valve pin ~) out of each exhaust pipe. [~ [~ 3. Remove pin and valve. ings.

Push out two rubber bush-

installation 1. Apply ,Scotch Grip Rubber Adhesive to two new rubber bushings and push into each exhaust pipe.

~75A

[~ 2. Lightly lubricate exhaust valve pin with oil. Position valve in each exhaust pipe with long side of valve down. Push pin through bushing and exhaust valve until flush with both sides of pipe. Check exhaust valve for freedom of movement. if the valve is not positioned properly (long lip down), will restrict exhaust flow and fail to prevent water from backing up into exhaust system. Boat performance could be adverse, ly affected, and major engine damagecould occur. 3. Install

6376

exhaust hoses and adaptor pipes.

6377

Engineleng

4-31

~78

Engine Coupler Replacement - SX Models Removal [~ if coupler is being replaced due to coupler failure (rubber hub of splined hub), check engine alignment after installing new coupler. 1. Removeengine from boat following instructions Removaland Installation in this manual.

in Engine

[~ 2. Cut tie strap ~) holding flywheel housing drain hose to starter motor, then remove starter. Removesmall screws along forward edge of bellhousing plate. 3. Unscrew outer nut on ground stud, and take off lock washer and electrical leads. Removeinner nut, lock washer and washer. Removesimilar ground stud hardware on opposite side of block. 4. Removepower steering cooler. Unscrew remaining flywheel housing bolts, lock washersand washers. Note position of clamps so they can be installed in original position. 5. Loosen bellhousing engine.

with a soft

hammer, and pull

off

6675

[~ 6. Unscrewsix nuts and lock washers, then pull coupler off flywheel. Installation DE] 1. Slide coupler onto crankshaft studs, install lock washers and nuts. Use a crowfoot wrenchand tighten nuts to 40-45 ft. Ibs. (54-61 N-m). 6710

6712

4-32

67~4 CobrEng/eng

2. Install flywheel housing. Place clamps in their orriginal positions and attach power steering cooler. Tighten screws to 28-36 ft. ~bs. (38-49 N-m}. ~ 3. Place washer, lock washer and nut on ground stud. Tighten inner nut to a torque of 20-25ft. Ibs. (27-34 N.m). Attach electrical leads to ground stud. install lock washer and tighten outer nut secure|¥. Install ground stud hardwareon opposite side of block. [1~] 4. Install small screws along forward edge of bellhousing plate and tighten to 60-84 in. Ibs. (6,7-9,5 N-m). Install starter motor and tighten screws to 24-30 ft. Ibs. (33-41 N.m). Attach flywheel housing drain hose to starter motor with a tie strap. !5. Install engine irm boat following instructions in EngineRemoval and Installation section in this manual.

Engine/en9

~ Safety Related

4-33

6711A

TorqueSpecifications - All Models The following specifications

are for screw sizes not shownotherwise:

SCREW SiZE No. 6 No. 10 No. 12 V4 s/16 3h

FT. LBS

iN. LBS.

N-m

2-3 3-4 5- 7 10- 12 18 - 20

7- 10 25-35 35-45 60 - 80 120- 140 220 - 240

0,8-1 3-4 4-5 7- 9 14- 16 24 - 27

Use a reliable torque wrench to tighten the parts listed to prevent straining or distorting the parts or possibly damagingthe threads. These specifications are for clean threads only. Dirty threads produce friction which prevents accurate measurementof tightness, it is important that these torque specifications be strictly observed. Overtightening to any extent maydamagethreads, thus preventing proper torque from being obtained, requiring replacement or repair of the damagedpart.

C FT. LBS. J [iN,

Adaptor- Oil Pressure Sender Alternator- Bracket to Pump Camshaft Sprocket Circulating Pump Cover, FlywheeU Housing Cover Plate, Oil Pump Cylinder Block Cover Distributor Clamp Exhaust Elbow Exhaust Manifold Fitting, Oin Withdrawl Tube Flywheel Bellhousing Flywheel Cover Front Mount to 8lock Fuel Pump intake ManifoEd Oil lnnet Tube-to-Pump Oil inlet "PabeBracket Oil Pan(1/4 x 20) Oil Pan (5/16 x 18) Power Steering PumpBracket Pulmey, Crankshaft Pulley, Circulating Pump Rocker Arm Rocker Arm Cover Starter Motor Starter Motor Bracket

LBSj

10-14 18-20 40-45 12-18 60-84 72-120 12-18 17-25 12-18 20-28 15-18 28-38 60-84 32-40 18-20 23-25 10-15 22-32 9-11 9-11 26-30 22-32 14-20 18=25 36-60 24-30 18-19

4-34

= =

14-19 24-27 55-61 17-24 6,7-9,5 8-16 17-24 23-34 16-24 27-35 20-24 38-49 6,7-9,5 43-54 24-27 31-34 14-20 30-43 13-14 13-14 35-41 30-43 19-27 24-34 4-6 33-41 22-28

Engine/eng

TorqueSpecifications- (Cont.) ( FT. LBS.J ~lN. LBS.1

Raw-water Pump Bracket Thermostat Housing Water Outlet Housing

12-18 12-16 10-15

17-24 16-22 14-20

Carburetor Connecting Rod 5.0 FL 5.8 FL Couple~r, Engine Exhaust Manifold Flame Arrestor Front Mount (top) Vibration Damper Withdrawl Tube to Fitting

10-14

14-19

19-24 40-45 40-45 20-26

26-33 54-61 54-61 27-35 3,4-4,5 68-95 95-122 20-24

30-40 50-70 70-90 15-18

m Cylinder Head(5.0 FL) Step 1 Step 2 Step 3 Cylinder Head(5.8 FL) Step 1 Step 2 Main Bearing Cap 5.0 FL 5.8 FL Front Mount

Engi.~/e.g

25-35 33,8-47,4 45-55 61,0-74,5 Tighten an additional 85°- 95° (1/4 turn) 129-143 143-151

95-105 105-112 60-70 95-105 60-75

-

Flame Arrestor to Carburetor Flywheel and Coupler

10-15

65-80 -

Oil Filter Sender, Oil Pressure Sender, Water Temperature Spark Plugs

One, Turn 10-14 18-22 10-15

4-35

81-95 129-142 81-102

7-9 14-20

After Contact 14-19 24-30 14-20

Engine Specifications 1. GeneralSpecifications Type - No. of Cylinder ............................. Bore and Stroke - 5.0 FL ........................... Bore and Stroke - 5.8 FL ........................... Piston Displacement- 5.0 FL ........................ Piston Displacement- 5.8 FL ........................ Cylinder No.{front to rear - starboard) ................. Cylinder No.(front to rear - port) ..................... Firing Order .................................... Compression Ratio - 5.0 FL ......................... Compression Ratio - 5.8 FL ......................... Fuel System - 5.0 FL .............................. FueJ System - 5.8 FL .............................. Thermostat Opens at ............................. Full Throttle Operating Range .......................

90° V - 8 4.00 in. x 3.00 in. 4.00 in. x 3.50 in. 302 Cu. In. (5.0 Liter) 351 Cu. In. (5.8 Liter) 1- 2- 3- 4 5- 6- 7 - 8 1 - 3 - 7- 2- 6- 5- 4- 8 8.4:1 8.3:1 Mechanical pump; Holley 2 BBL. Mechanical pump; Holley 4 BBL. 160° F 4000-4400 RPM

2. Engine Dimensions, Fits and Adjustments Cylinder Head: Combustion ChamberVolume (cc) - 5.0 FL .......... Combustion ChamberVolume (cc) - 5.8 FL .......... Valve Guide Bore Diameter ...................... Valve Seat Width Intake and Exhaust ........................ Valve Seat Angle - Intake and Exhaust ............. Valve Seat Runout - Maximum ................... Valve Arrangement (Front to Rear) Right .................................. Left ................................... Gasket Surface Flatness ........................ Gasket Surface Finish

RMS* .....................

67.5-70.5 63.4-66.4 0.3433-0.3443in. 0.060-0.080 in. °45 0.0020 in. I-E-kE-I-E-I-E E-I-E-I-E-m-E-I 0.003 inch in any 6 inches or 0.006 inch overall 60-150

* RMS- Root Mean Square Valve Rocker Arms, PushRod and Lifters: Rocker Arm Lift Ratio .......................... Valve Push Rod Runout - Maximum ............... Hydraulic Lifter Leakdown Rate ...........................

Hydraulic Lifter Standard Diameter ........................ Clearance to Bore ......................... Service Limit ............................

1 =61:1 0.015 in. 5-50 seconds maximum measuredat 1As in. plunger travel with 50 Ibs. load and leak down fluid in tappet 0.8740-0.8745in. 0.0007-0.0027 in. 0.005 in.

EngineSpecifications Cont. Valve Rocker Arms, Push Rod and Lifters Cont: Hydraulic Lifter Collapsed Gap 5.0 FL Allowable ............................... Desired ................................. 5.8 FL Allowable ............................... Desired ................................. Valves: Valve Stem Diameter Intake .................................. Exhaust ................................ Valve Face Angle .............................. Valve Stem to Valve Guide Clearance Intake .................................. Exhaust ................................ Wear Limit .............................. Valve Head Diameter Intake - 5.0 FL ............................ Intake - 5.8 FL ............................ Exhaust- 5.0 FL .......................... Exhaust- 5.8 FL .......................... Valve Face Runout (Maximum) ................... Valve Face Runout (Maximum) ................... Valve Spring Free Length - Approximate intake - 5.0 FL ............................ intake - 5.8 FL ............................ Exhaust - 5.0 FL .......................... Exhaust - 5.8 FL .......................... Valve Spring Out-of-Square Maximum ............................... Valve Spring Pressure - Lbs. at Specified Length intake- All Models ........................ intake - 5.0 FL ............................ Untake - 5.8 FL ............................ Exhaust - All Models ...................... Exhaust All models ....................... Service Limit ............................ Valve Spring AssembledHeight - Pad to Retainer intake .................................. Exhaust ................................

0.071-0.193in. 0.096-0.165in. 0.098-0.1!;)8in. 0.123-0.173in,

0.3416-0.:3423in. 0.3411-0.:3418in. ° 44 0.0010-0.0027in. 0,0015-0.0032in. 0.0055 in. 1.770-1.7!;)4in. 1.837-1.847in. 1.439-1,463in. 1.837-1.847in. 0.0020 in, 0.0020 in, 2.06 in. 2.056 in. 1.86 in. 1.877in. ~’~ (0.078)in. 78+4 Ibs. @1.78 in. 204-+10Ibs. @1.33 in. 218-+10Ibs. @1.33 in. 75-+4 Ibs. @1.60 in. 205---10 Ibs. @1.15 10% Pressure Loss @Spec. Length 1.18 in. 1.60 in.

Camshaft and Bearings: Camshaft No. No. No. No. No.

Journal Diameter Standard 1 Bearing ............................ 2 Bearing ............................. 3 Bearing ............................ 4 Bearing ............................ 5 Bearing ............................

2.0805-2.0815in. 2.0655-2.0665in. 2.0505-2.0515in. 2.0355-2.0365in. 2.0205-2.0215in.

Engine

Specifications

Cont

.....

Camshaftand BearingsCont: CamshaftJournal to Bearing Clearance ............ Camshaft End Play ............................ CamshaftLobeLift 5.0 FL Intake .................................. Exhaust ................................ 5.8 FL Intake .................................. Exhaust ................................ MaximumAllowable Lobe Lift Loss ............... Bearing Inside Diameter Bearing No. 1 ............................ Bearing No. 2 ............................ Bearing No. 3 ............................ Bearing No. 4 ............................ Bearing No. 5 ............................ Camshaft Journal MaximumRunout T.i.R.** .................. CamshaftBearing Location No. 1 Bearing ............................ Timing Chain Deflection - Maximum...............

0.001-0.003in. ServiceLimit - 0.006in. 0.001.0.007in. ServiceLimit - 0.009in. 0.2600in. 0.2780in. 0.2780in. 0.2830in. 0.005in. 2.0825-2.0835 in. 2.0675-2.0685 in. 2.0525-2.0535 in. 2.0375-2.0385 in. 2.0225-2.0235 in. 0o005in. 0.0050-0.0200 in.* 0.500in.

* Distancein inchesthat the front edgeof the bearingis installed toward the rear from the front face of the cylinder block. ** Total indicated Reading CrankshaftMain Bearings: Journal Clearance 5.0 FL- No. 1 Bearing Desired ................................. Allowable ............................... 5.0 FL- All others Desired ................................. Allowable ............................... 5.8 FL Desired ................................. Allowable ............................... Wall Thickness 5.0 FL - No. 1 Bearing ........................ All Others ............................... 5.8 FL- No. 1 Bearing ........................ All Others ...............................

0.0001-0.0015in. 0.0001.0.0020in. 0.0005-0.0015 in. 0.0005.0.0024in. 0.0008-0.0015 in. 0.0008-0.0026 in. 0.0961-0.0966 in, 0.0957-0.0962 in. 0.0957-0.0960 in. 0.0957-0.0962 in.

EngineSpecifications Cont. C~ankshaft and Flywheel: Main Bearing Journal Diameter 5.0 FL .................................. 5.8 FL .................................. Main Bearing Journal Out-of-Round Max ........... Maximum Runout T.I.R.** .................. Taper Limit .................................. Surface Finish Maximum ....................... Connecting Rod Journal Diameter 5.0 FL .................................. 5.8 FL .................................. Connecting Rod Journal Out-of-Round Maximum ............................... Connecting Rod Journal Taper Maximum ............................... Surface Finish Limit ........................... Thrust Bearing Journal Length ................... Main Bearing Journal Thrust Face Runout Limit ........................ Face Finish .............................. Crankshaft to Rear Face of Block Runout T.I.R.** Maximum ............................... Crankshaft End Play Clearance ....................

2.2482-2.2490in. 2.9994-3.0002in. 0.0006 in. 0.002 0.0004 per in. 12 RMS 2.1228-2.1236in. 2.3103-2.3’111in. 0.0006 per in. 0.0006 per in. 12 RMS 1.137-1.139in. 0.001 25 Front 20 Rear RMS 0.005 in. 0.004-0.0013in. Service Limit - 0.012 in. max.

** Total Indicated Reading G~nnecting Rod: Piston Pin Bore i.D. - Standard .................... Bearing Bore Diameter 5.0 FL ................................... 5.8 FL ................................... Bearing Bore Out-of Round and Taper ............... Connecting Rod Length - Center to Center 5.0 FL ................................... 5.8 FL .................................. Twist Total Difference - Maximum................. Bend Total Difference - Maximum.................. Rod Assembled to Crankshaft Side Clearance ............................ * Pin, bushing and crankshaft bearing bore must be parallel, and in the samevertical plane, within the speck lied total difference at ends of an 8-inch long bar measured 4 inches on each side of rod.

0.9096-0.9112in. 2.2390-2.2398in. 2.4265-2.4273in. 0.0004 in. 5.0885-5.0915in. 5.9545-5.9575in. 0.024 in. 0.012 in.* 0.010-0.020in. Service Limit - 0.023 in.

EngineSpecifications Cont.

-

-

--

Connecting Rod Bearings: Bearing to Crankshaft Clearance Allowable ............................... Desired ................................. Wall Thickness - Standard .................. 0.002 Undersize ..........................

0.0008-0.0025in, 0.0008-0.0015in, 0.0572-0.0577in, 0.0582-0.0587in.

Pistons: sPiston Diameter Coded Red 5.0 FL .................................. 5.8 FL .................................. Coded Blue 5.0 FL .................................. 5.8 FL .................................. 0.003 Oversize 5.0 FL .................................. 5.8 FL .................................. Piston to Cylinder Bore Clearance ................. Piston Pin Bore Diameter ....................... Ring Groove Width, Compression 5.0 FL Top .................................... Bottom ................................. Oil Ring ................................ 5.8 FL Top .................................... Bottom ................................. OiJ Ring ................................

3.9984-3.9990in. 3.9978-3,9984in. 3.9996-4.0002 in. 3.9990-3.9960 in, 4.0020-4.0026 in. 4,0014-4.0020 in. 0.0018-0.0026 in. 0.9124-0.9127 in. 0.060-0.061 in. 0.060-0.061 in. 0.1587-0.1597 in. 0.080-0.081 in. 0.080-0.081 in. 0,1880-0.1890 in.

Measuredat the piston pin bore centerline at 90° to the pin Piston Pin: Piston Pin diameter - Standard ................... 0.001 Oversize ........................... 0,002 Oversize ........................... Piston Pin Length ............................. Piston Pin to Piston Clearance 5.0 FL .................................. 5.8 FL .................................. Piston Pin to Connecting Rod Bushing Clearance .....

4-40

0.9120-09123in. 0.9130-0.9133 in. 0,9140-0,9143 in. 3.010-3.040 in. 0.0002-0.0004 in. 0.0003-0.0005 in, Service Limit - 0.0008 in. interference Fit

Ertgine/eng

Engine Specifications Cont.

---

Piston Rings: 5.0 FL Top Compression Ring Width ................. Bottom Compression Ring Width .............. 5.8 FL Top Compression Ring Width ................. Bottom Compression Ring Width .............. Top Compression Ring Side Clearance .............. Bottom Compression Ring Side Clearance ........... Service Limit ................................. Oil Ring Side Cmearance ......................... Top Compression Ring Gap ....................... Bottom Compression Ring Gap ................... Oim Ring (Steel Rail) Gap ........................

0.0577-0.0587in. 0.0577-0.0587in. 0°077-0.078in. 0.077-0.07t3in. 0.002-0.004in. 0.002-0.004in. 0.002 max, increase in total clearance Snug 0.010-0.020in. 0.010-0.020in. 0.015-0o055in.

Cylinder Block: Cylinder Bore Diameter 5.0 FL .................................. 5.8 FL .................................. Maximum Out-of-Round ........................ Maximum Taper .............................. Crankshaft to Rear Face of Block Runout T.I.R. Maximum .......................... Lifter Bore Diameter ........................... Main Bearing Bore Diameter 5.0 FL .................................. 5.8 FL .................................. Distributor Shaft Bearing Bore Diameter 5.0 FL .................................. 5.8 FL .................................. Head Gasket Surface Flatness .................... Head Gasket Surface Finish RMS** ................ Cylinder Bore Surface Finish RMS** ...............

4.0004-4.0052 in. 4.0000-4.0048 in. 0.0015 in. Service Limit - 0.005 in. 0.001 in. Service Limit - 0.010 in. 0.005 in. 0.8752-0.8767in. 2.4412-2.4420in. 3.1922-3.1930in. 0.4525-0.4541in. 0.5155-0,51171 in. O.003in. in any 6 in. or 0.006 in. overall 60-150 18-38

** RMS- Root Mean Square Oil Pump: Relief Valve Spring Tension (Lbs. @Specified Length) 5.0 FL .................................. 5.8 FL .................................. Driveshaft to Housing Bearing Clearance ........... Relief Valve Clearance .......................... Rotor Assembly End Clearance ................... Outer Race to Housing Clearance (Radial) ...........

10.6-12.2 @1.704 in. 18.2-20.2 @2.49 in. 0.0015-0.0030in. 0.0015-0.0030in. 0.001-0.004in. 0,001-0.013in.

NOTES

4-42

Section 5 5.0 Fi, 5.8 Fi andFSi Tableof Conteni:s Circulating PumpReplacement........................... Core Plugs ........................................... Crankshaft Rear Oil Seal ............................... Cylinder Head.......................................... Diagnosis and Testing Camshaft Lobe Lift ................................... Compression Test ................................... PCVSystem .......................................... Engine Coupler Replacement ........................... Engine Specifications .................................. Exhaust (Flapper) Valve Replacement.................... Exhaust Hose and intermediate Pipe Replacement......... Exhaust Manifold Replacement........................... Front Cover and Timing Chain ........................... Front Engine Mounts ................................... Height Adjustment ................................... Front Oil Seal ......................................... High-Rise Exhaust Elbow Replacement................... Intake Manifold ......................................... Oil Pan ............................................... Oil Pump............................................. Torque Specifications .................................. Valve Clearance Check ................................. Valve Lifter ........................................... Valve Rocker Arm and Cover ............................ Valve Spring, Retainer and Stem Seal ....................

5-6 5-23 5-18 5-9 5-24 5-25 5-26 5-32 5-36 5-31 5-30 5-5 5-12 5-27 5-29 5-14 5-29 5-3 5-15 5-16 5-34 5-21 5-22 5-19 5-11

Safety Warnings Beforeworkingon anypart of the engine, readthe section called Safetyat the endof this manual. Unlessinstructed otherwise, alwaysdisconnect the battery cables from the battery before workingon electrical systemto preventpossible sparks or arcing in the enginecompartment. Before starting engine after repair or maintenanceprocedures,alwaysmake sure ,engine compartment is free of fuel vaporsto prevent possible fire and explosion. Whenworking on an engine that is running or being cranked, use extreme care to avoid getting hands,fingers or clothing caughtin the alternator, power steering pump,supply pump,and circulating pumpbelts, pulleys and other movingparts.

Engine/eng

5-1

Materials Required Cleaning solvent DuraPlus Synthetic Motor Oil Gasket Sealing Compound Loctite primer or equivalent Loctite or equivalent Scotch-Grip Rubber Adhesive RTVSiRicone Rubber Sealant

OTCTools Required T58L-101-APilot Bearing Puller T58P-6316-D Damper Remover T59L-100-BPilot Bearing Puller T61 P-6019-B Cover Alignment Tool T65P-6701-AOil Seal Installer "F70L-6500-ALifter Puller T70P-6049-A Valve Spring Compressor rToP-6B070-ASeal Installer TTOP-6B070-B Seal Remover T71P-6513-B Hydraulic Lifter Compressor T74P-6666-A Plug Wire Remover T77L-9533-B Slide HammerTool T79T-6316-A DamperInstaller T82L-6701-AOil Seal installer Order from: OTCDivision of SPXCorporation 655 Eisenhower Dr. Owatonna, Minnesota 55060 Phone: 1-800-533-0492 or 1-800-533-5338

5-2

Engine/eng

intake Manifold Removal "1. Refer to Upperintake Manifold Remova!in the Fuel Systems Workshop Manual 2. Removethe two screws securing thermostat housing adapter to intake manifold. 3. Removeattaching bolts,

and remove intake manifold.

If necessary to pry manifold awayfrom cylinder heads, do not damagegasket sealing surfaces. 4. Removeand discard intake manifold gaskets and seals. Cleaning Removeall gasket material from the machined surfaces of the manifold. Clean the manifold in a suitable solvent and dry it with compressedair. Inspection Inspect the manifold for cracks, damagedgasket surfaces, or other defects that would makeit unfit for further service. Replace all studs that are stripped or otherwise damaged. Removeall filings and foreign matter that mayhave entered the manifold as a result of repairs. |nstailation 1. Clean mating surfaces of intake manifold, cylinder head%and cylinder block. Use a solvent such as Ford Spot Remover(B7A19521-A), Cleaning solvent or similar degreasing agent.

Engine/eng

5-3

2. Apply a 1/s in. diameter bead of silicone rubber sealer ~) (C3AZ-19562-Aor B) in and along the joint, the full width of the cylinder block seal mounting surface (~) (four corners) as shown. [~ 3. Install the cylinder head to manifold gaskets ©, and the front and rear intake manifold to cylinder block seals ~). Apply 1A~in. bead of sealer (~) at the outer end of each intake manifold seal for the full width of the seal. This sealer sets up within 15 minutesafter application, so assembly should proceed promptly. 4. Carefully lower intake manifold into position. Whenintake manifold is in place, run finger around seal area to be sure seals are in place. If seals have shifted, removemanifold and reposition seals. [~ 5. Be sure intake manifold gaskets are properly aligned, then install attaching bolts. Tighten snugly to manifold, then tighten bolts in recommendedsequence to proper torque. Repeat torque sequence, tightening bolts again to original torque value. Because the center manifold bolts becomeloose, re-torque manifold bolts seasonally. 6. Install manifold.

@ DR2215

thermostat housing and adaptor assembly on intake

7. Refer to Upperintake ManifoldInstallation in the Fuel Systems Workshop Manual. 8. Makesure engine compartment is free of fuel vapors. Start engine and checkfor fuel leaks. Checkand adjust ignition timing. Checkengine for cooling leaks. [~ 9. After engine reaches normal operating temperature, retighten manifold bolts and nuts to proper torque in correct sequence.

f

Front

®,,

32349

Safety Related

5-4

Engine/eng

32354

32355

32357

Exhaust Manifold Replacement Removal r3-~ 1. Loosen six hose clamps (~ holding exhaust hoses to exhaust elbow (~). [~ 2. Lubricate lower hose and exhaust pipe with a soapy’water solution, and slide hose downonto pipe. 3. Removeexhaust elbow from high-rise

elbow hose.

32345

4. Starboard Only: Removescrews securing ECAto high-rise elbow. ET~ 5. Removethe four screws ® securing high-rise Removethe elbow and discard gasket.

elbow O.

L-~ 6. Loosen clamp and pull water hose off front of mani;fold. 7. Pull spark plug leads off spark plugs. Mark plug wires to ensure correct firing order. Eg~ 8. Unscrew eight Iocknuts and lock washers holding manifold to mounting studs. Pull manifold off studs.

32359

9, Removeand discard exhaust manifold gasket.

32356

Eng~ne/eng

5-5

32358

InstaHatior| [~ 1. Install a new exhaust manifold gasket. Gasket ports must completely align with exhaust openings. Gasket can be correctly installed in only one position, if improperly installed, gasket will block off part of each exhaust port and/or block access to spark pUugs. [~] 2. Slide manifold onto studs. Attach lock washers and Iocknuts, and tighten Iocknuts to 20-26 ft. Ibs. (27-35 N-m). 3. Coat a new gasket with Gasket Sealing Compound and place it on manifold. Install high-rise elbow and tighten screws to 12-18 ft. Ibs. (16-24 N-m}. Starboard Only: Attach ECAto high-rise elbow. I~ 4. Attach water hose to nipple tighten clamp.

at front

25924A

of manifold and

5. Attach spark plug wires to plugs. Makesure firing correct.

order is

EEl 6. Lubricate upper (large diameter) outside surface of exhaust elbow with a soapy water solution, and push elbow into high-rise elbow hose until it seats.

25923

[~ 7. Lubricate lower end of exhaust elbow and slide lower hose up onto elbow. Position hose so that it equally covers elbow and exhaust pipe. Z~ DE] 8. Install the six hose clamps and tighten them securely. Run engine and check for exhaust leaks.

Circulating

PumpReplacement 15527

Removal 1. Drain all water from engine block. 2. Loosen the circulating pump pulley bolts, but don’t removethem at this time. Note, belt tension will keep the pump from turning while bolts are removed. 3. Release tension on the alternator pump belts, then remove them.

and power steering

4. Unscrewthe pulley bolts, and smidethe pulley offthe circulating pump hub.

15545

5. Removethe two power steering bracket bouts.

Z~ Safety Related

5-6

Engine/eng

15546

[1-~ 6. Removebrace from alternator pump. [~ 7. RemoveTorx head bolt steering pump.

15547

25921

bracket to power steering

~ and spacer and remove power

L-~ 8. Removealternator brace from circulating ing bolt and mockwasher.

pumpby remov-

~’J 9. Loosen hose damp, and pull large hose off circulating pump.

25920

10. Take out alternator bracket bolts. Removealternator and disconnect electrical leads at back of alternator. Set alternator aside. J~] 11. Removeall pump mounting bolts. Lightly strike pump with soft hammerto free it from the mounting gasket. Take off pump, then remove and discard gasket. installation 1. Thoroughly clean gasket surface on block. Coat both sides of a new gasket with Gasket Sealing Compoundand position it on block, Carefully align bolt holes and water passages.

15550

[~ 2, install circulating pump. Screw in all bolts except those that attach the alternator and power steering pump brackets. Tighten bolts to 1:.L18 ft. Ibs. (16-24 N-m).

15658

En,~ine/eng

5-7

15657

15529

[~ 3. Push marge water hose onto pump inlet securely.

15531

and tighten clamp

4. Place spacer and Torx head bolt behind rear power steering pump bracket and secure to block. Attach two power steering pumpbracket screws and lock washers. 5. Attach the alternator and alternator bracket to the circunating pumpwith screws, lock washers and flat washers. Tighten the screws to 18-20 ft. Ibs. (24-27 N.m). 25921

6. Attach electrical leads to back of alternator. 7. Attach aUternator brace to circulating tighten pivot bolt at this time.

pumpcover. Do not

[~ 8. Attach power steering pumpbrace to alternator with screw and lock washer.

bracket

[~ 9. Align the pulley and pumphub screw holes, then slide the pulley onto the pump. Install the screws and lock washers and tighten them to 14-20 ft. Ibs. (19-27 N.m). 10. nnstall the power steering pumpbelt and position it in the innermost pulley grooves. Install the alternator belt in the next outer groove.

15528

The two belts are different lengths. The power steering pumpbelt is longer and goes on first. 11. Tension both belts as recommended;see General Information section. Tighten all power steering and alternator bracket bolts securely. 12. Run engine and check for water leaks. 15527

5-8

Engine/eng

Cylinder Head Removal 1. Completelydrain cooling systemto ensureno water remainsin the intake manifold, cylinder heads, exhaustmanifolds, hosesor block. 2. Disconnect the spark plug leads at the plugs. Removethe exhaustmanifolds, then spark plugs. 3. Removethe upper and lower intake manifolds. See Upper Intake Manifold Removalin the F-uei SystemService Manual.See IntakeManifoldin this chapter.

DR4858

®

4. Removeany components, brackets or clamps that may be attached to the front or rear of the cylinder heads. Note their position so that they can be properlyreinstalled. 5. Remove the rocker armcovers. Discard the old gaskets. [~ 6. Loosenthe rocker armbolts so that the rocker armsmaybe rotated. Removethe push rods in sequenceso they can be installedin their original positions. 7. 5.0 Uter Only: Remove and inspect cylinder headbolts. Retainstandardheadbolts (~); they can be reused.Discan~"torque to yield" headbolts (~); replace themwith new"torque to yield" headbolts. Lift the headoff the block. Discardheadgasket. 8. 5.8 Liter Only: Remove the cylinder headattachingbolts andlift the headoff the block. Discardheadgasket. Installation r~ 1. Cleanthe cylinder head,intake manifold, rocker armcovers and cylinder block gasket surfaces. If the headwasremoved for a cylinder headgasket replacement,checkflatness of the headand block gasket surfaces. Surface mustnot deviate morethan 0.003 in. (0,076 mm)inany 6 in. (152,4 mm)area, and .006 in. (0,152 ram)overall. 2. A specially treated compositiongasket is used. Do riot apply sealer to a compos~on gasket. Position the newheadgasket over the alignmentdowels.Place the headon the block andinsert the attachingbolts.

Eng~ne/eng

5-9

___]

®

[~ 3. Thecylinder headbolts are tightened in two steps for all 5.8 liter engines,andin either twoor three steps(torqueto yield method}for the 5.0 liter enginedependingon whichtype head bolts are used.Followthe illustrated torquepattern, andtighten as follows: ~WARNING- Donot reinstall torqueto yield headbolts. Torque to yield headbolts mustbe replacedoncethey are removed. ¯ 5.0 Liter Step 1. Step2. Step3.

Engineswith torqueto yield bolts: 25-35ft. lb. (33,8 - 47,4 Nm) 45-55 ft. lb. (61,0- 74,5 Nm) TurnalUbolts in sequence additional 85 o _ 95° (¼ turn} ¯ 5.0 Uter Engineswith standardhex headbolts: Step 1. 55-65ft. lb. (74,6 - 88,2 Nm} Step 2. 65-72ft. lb. (88,2 - 97,6 Nm}

DR4860

4

e 5.8 Uter Engines: Step 1. 95-105 ft. lb. (128,8- 142,4 Nm} Step 2. 105-112ft. lb. (142,4- 151,9 Nm) 4. Cleanthe pushrods in solvent. Blowout the oil passage in the pushrods with air. Checkthe endsfor nicks, groves, roughness or excessivewear. Visually checkpushrods for run-out or with a dial indicator. Replacepushrod if run-out exceeds0.015 in. (0,381 ram)at any point. Donot attempt to straightenandreuse pushrods. 5. Lubricate the rocker armendof pushrod with FordMultipurpose GreaseDOAZ-19584-AA or equivalent, and install themin their original positions.

DR2599

6. Lubricate the valve stemendswith Ford MultipurposeGrease DOAZ-19584-AA or equivalent. 7. Lubricate the rocker armsand fulcrum seats with Ford Multipurpose GreaseDOAZ-19584-AA or equivalent. Install the rocker armsfollowing the procedureunderValve Rocker ArmInstallation. 8. Clean the rocker arm cover gasket surfaces. Secure new gasketsin the covers with gasket sealer to ensureproper hole alignment.Unstall the covers; tighten the mountingscrewsto 3660 in. lb. (4-6 Nm). 9. Install the intake manifold.SeeIntake Manifoldin this chapter. 10. Install any components,brackets, or clampsthat wereremoved. 11. install spark plugs, andthe exhaustmanifolds,then connect the spark plug leads. 5-10

E.gi~/e.~

Valve Spring, Retainer and Stern Seal

\

Removal Broken valve springs, or damagedvalve stem seals and retainers, may be replaced without removing the cylinder head, provided damageto the valve or valve seat has not occurred. ’1. Removerocker arm cover. 2. Removethe applicable spark plug and bring the piston to the top of the bore to prevent accidental loss of the valve into the cyi inder.

DR4861

:3. Removethe rocker arm fulcrum bolts, fulcrum seats, rocker arms and push rods from the applicable cylinder. 4. install an air line with an adapter in the spark plug hole and apply air pressure to the cylinder. Failure of the air pressure to hoJdthe valve in the closed position is an indication of valve seat damage,and requires removal of the cylinder head. 5. Install the fulcrum bolt and position Valve Spring Compressor Tool T70P-6049-Aor equivalent as shown. Compressthe valve spring and removethe retainer locks, spring retainer, sleeve and valve spring. 6= Removeand discard the valve stem seal. [~ If air pressure has forced the piston to the bottom of the cylinder, any removal of air pressure will allow the valve to fall into the cylinder. A rubber band, tape or string wrappedaround the end of the vaJve stemwill prevent this condition and will still allow enoughtravel to check the valve. 7. inspect the valve stem for damage.Rotate the valve and check the stem tip for eccentric movementduring rotation. Move the valve up and down through normal travel in the valve guide and check the stem for interference, if the vaJve has been damaged, it’H be necessary to removethe cylinder head. installation 1. if the condition ,of the valve stemproved satisfactory, lubricate the valve stem with the recommendedengine oU. Hold the valve in the closed position and apply air pressure within the cylinder. E4~2. install a newvalve stemseal on the valve guide. Seall must be bottomedon guide. Place the spring in position over the valve, and install the spring retainer and sleeve. Compressthe valve spring and install the spring retainer [ocks. Removethe compressor tool and fulcrum bolt.

Engine/eng

5-’1 1

DR4862

3. Lubricate the upper push rod ends with Ford Multi-Purpose Grease DOAZ-19584-AA or equivalent, and install the push rod. Apply the samegrease to the tip of the valve stem. 4. Apply Ford Multi-Purpose Grease DOAZ-19584-AAor equivalent to the rocker arms and fulcrum. Install the rocker arms, fulcrum and fulcrum bolts. Tighten the bolts to 18-25 ft. Ibs. (24-34 N.m). 5. Turn off the air and removethe air line and adapter. Install the spark plug and connect the plug wire. 6. install the rocker arm cover using new gaskets; follow the procedure under Rocker Armand Cover Installation,

DR4863

Front Cover and Timing Chain Removal 1. Refer to Circulating PumpRemovalsection. Perform aln steps except removal of the pump. Leave it attached to the front cover. 2. Remove the crankshaft pulley. Unscrew the damper attaching bolt and washer. Attach DamperRemoverT58P-6316-D or equivalent, and pull vibration damperoff crankshaft° 3. Removethe oil pan-to-cylinder block front cover attaching bolts. Use a thin-bladed knife to cut the oil pan gasket flush with the cylinder block face prior to separating the cover from the block. 4. Removethe cylinder front cover and circunating assembly. Discard the front cover gasket.

pumpas an

5. Checkthe timing chain deflection, if deflection exceeds0.500 in. (12,7 ram), replace the chain and sprockets.

5" 1 2

Engine/eng

[3 6. Crank the engine until are positioned as shown.

the timing marks on the sprockets

7. Removethe camshaft sprocket cap screw, washers and fuel pumpeccentric. Slide both sprockets and the timing cha;in forward, and remove them as an assembmy. installation ~2~ 1. Position the sprockets and the timing chain on the camshaft. Be sure the timing marks on the sprockets are positioned as shown.

DR4864

[3~ 2. Install the fuel pump eccentric, washers and camshaft sprocket cap screw. Tighten the sprocket cap screw to 40-45 ft. Ibs. (55-61 N.m). 3. Clean the cylinder front cover, oil pan and the cylinder block gasket surfaces. Clean the oil pan gasket surface where the oil pan and front cover fasten. install a newoil seal following procedures under Front Oi:l Seal Remova|and JnstaJiation. 4. Lubricate the timing chain and sprockets with heavy engine oil.

DR4865

5. Coat the gasket surface of the oil pane with sealer. Cut and position the requh’ed newgasket on the oil pan and apply sealer at the corners. Install the pan sealer as required. Coat the gasket surfaces of the block and cover with Ford Perfect Seal Sealing CompoundB5A-199554-A (ESR-M18P2-A} or equivalent, and position a newgasket on the block. 6. Position the cylinder front cover on the cylinder block. Usecare wheninstalling the cover to avoid seal damageor possible gasket rnislocation. F=~-3

L~=~_J7. Install

DR4886

the cylinder front cover-to-seal alignment using

F¥ont Cover Aligner

Tool T61P-6019-B

or equivalent.

8. at maybe necessary to force the cover downwardto slightly compress the pan gasket. This operation can be facilitated by vising a suitable tool at the front cover attaching hole Jocal:ions. 9. Coat the threads of the attaching screws with Ford Perfect Seal Sealing CompoundB5A-19554-A (ESR-M18P2-A) or equivalent atnd install the screws. While pushing in on the alignmenll tool, tiighten the oHpan-to-cover attaching screwsto 9-11 ft. Ibs. 113-14 N-m). Tighten the cover-to-cylinder block mounting screws to 9-11 ft. Ibs. (13-14 N-m). Removethe alignment tool. 10. Apply Ford Multi-Purpose Grease DOAZ-19584-AA or equivalent to the oil seal rubbing surface of the vibration damperinner hub to prevent damage to the seal and to the front of the crankshaft for damperinstallation.

E~,~i.~/~.g

5-13

[i] 11. Line up the crankshaft vibration damperkeywaywith the key on the crankshaft. Install the vibration damperon the crankshaft using Damper Remover/Replacer Tool l’79T-6316-A or equivalent. Install the cap screw and washer. Tighten the screw to 70-90 ft. Ibs. (95-322 N-m). Install the crankshaft pulley. 12. Completethe remaining steps under Circulating Pumpinstallation. 13. Operate the engine at a fast idle to bring the engine up to operation temperature. Checkand adjust ignition timing to specifications in Electrica|/|gnJtion Workshop Manualunder initial Timing Set Procedure.

\ DR4867

Front Oil Seal Removal 1. Removethe crankshaft pulley from the vibration damper. Removethe damper attaching screw and washer, install the puller on the crankshaft vibration damperand removethe vibration damper. []~ 2. Place the Front Cover Seal Remover I’70P-6B070-B or equivalent onto the front cover plate over the front seal as shown. Tighten the two through-bolts to force the seal puller under the seal flange.

DR4868

3. Alternately tighten the four puller bolts one-half turn at a time as shownto pull the oil seal from the front cover. installation ~] 1. Coat a new front cover plate oil seal with Ford MultiPurpose Grease DOAZ-19584-AA or equivalent. Place the front oin seal onto Front Cover Seal Replacer T70P-OB070-A or equivalent. Place the sleeve and seal onto the end of the crankshaft and push it toward the engine until the seal starts into the front cover. [T~ 2. Place the installation screw, washer and nut onto the end of the crankshaft. Threadthe nut against the washerand installer sleeve to force the seal into the front cover plate. Removethe installation tool from the crankshaft. 3. Apply Ford Multi-Purpose Grease DOAZ-19584-AAor equivalent to the oil seal rubbing surface of the vibration damperinner hub to prevent damageto the seal. Apply a white lead and oil mixture to the front of the crankshaft for damperinstallation. 4. Line up the crankshaft vibration damperkeywaywith the key on the crankshaft, install the vibration damperon the crankshaft. Install the cap screw and washer. Tighten the screw to 70-90 ft. Ibs. (95-122 N-m). Install the crank pulley. Makesure the pulley bottomed on the damper pilot.

DR4869

Oil Pan Removal 1. Removeengine from boat following procedures in Engine Removaland installation section found elsewhere in this, workshop manual. 2. Drain the crankcase. Unscrewthe dipstick tube. 3. Removethe oil pan attaching bolts and removethe pan braces and pan. 4. Refer to cleaning and inspection procedures. Checkthe gasket surface for damagecaused by overtightened bolts. Straighten the surface as required to restore original flatness. Cleaning Scrape any dirt or metal particles from inside of pan. Scrape all old gasket material from the gasket surface. Washpan in a solvent and dry it thoroughly. Inspection Checkthe pan for cracks, holes, damageddrain plug threads, or a damagedgasket surface. Inspect for damage(uneven surface) at the bolt holes caused overtorquing mounting bolts. Straighten surfaces as required. Repair any damage,or replace the pan if repairs cannot be, made satisfactorily. Ilnstallation 14~ 1. Clean the gasket surfaces of block and oil pan. Coat the block surface and oil pan gasket surface with oil-resistant sealer. Position oil pan gasket on cylinder block. 14-~ 2. Hold the oil pan in place against block and place par= brace against pan. Install a bolt finger tight on eachside of oil pan to hold it in place, then install the remainingbolts. Tighten th,e bolts Fromthe center outward in each direction. Tighten 1/4-20 bolts to ’9-11 ft. Ibs. (13-14N-m). Tighten¥1~-18bolts to 9-11 ft. Ibs. (13-14 N.m). 15-~ 3. Install dipstick tube fitting to pan; leave screw loose. Orient fitting and attach dipstick tube. Thentighten both fitting screw and flare nut to 15-18 ft. lbs. (20-24 N-m).

DR2673

,4. Fill engine to proper level with recommended engine oil. !5. install engine into boat following procedures in Engine Remova| and installation section. Start engine and check for leaks.

1 31576

Oil Pump Removal 1. Removeengine from boat by following Removaland Installation section.

procedures in Engine

2. Removethe oil pan and related parts following the procedure under Oi| Pan Removal. [~ 3. Removeoil

pump inlet

tube and screen assembly. DR4591

[~ 4. Unscrew oil pump mounting screws. Remove pump and intermediate driveshaft. I

Disassembly 1. Removethe four screws and washers securing the oim pump cover to the oil pump, then oil pumpcover. 2. Removeoil pumpouter rotor and rotor shaft assembly from the oil pump housing. 3. Remove the cotter pin that secures the relief valve plug in the oil pump housing. To remove the plug, drilm a small hone and insert a self-tapping screwin the relief valve plug. Use pliers to removeplug from oil pumphousing. Use care to prevent the loss of the relief valve spring. 4. Removespring and relief

2 DR45g0

valve from oil pumphousing.

Cleaning Washall parts in solvent and dry them thoroughly with compressed air. Use a brush to clean the inside of the pumphousing and the pressure relief valve chamber. Ensure all dirt and metal particles are removed. inspection 1. Refer to Specifications for clearances and service limits. 2. Check the inside of the pumphousing and the outer race and rotor for damageor excessive wear. 3. Check the mating surface of the pumpcover for wear. If the cover mating surface is worn, scored or grooved, replace the cover. 32364

~] 4. Rest rotor assembly on fiat surface. Measuretip clearance with a feeler gauge. Tip clearance must not exceed0.004 in. (0,10 ram). [~ 5. With the rotor assembly installed in the housing, measure the outer race to housing clearance ~). Your feeler gauge reading must be 0.001-0.013 in. (0,03-0,33 ram).

5-16

r~ 6. Place a straight edge (~) over the rotor assembly and the housing. Measurethe clearance (rotor end play) ©, between the :straight edge and the rotor and outer race. Your reading must be 0.001-0.005in. (0,03-0,13 ram). 7. Check the driveshaft to housing bearing clearance by measuriing the O.D. of the shaft and I.D. of the housing bearing. Correct clearance is 0.0015-0.0029in. (0,04-0,07 mm). 8. if the pumpfails either Step 4, 5, 6 or 7, replace the oil pump ,assembly. The outer race, shaft and rotor are replaceable only as ,an assembly. 9. Inspect the relief valve spring for a collapsed orworn condition. ,Checkthe relief valve spring tension. e 302 cu. in. (5.0 liter) engines:1.74 in. (44,2 mm)length with a 10.6-12.2 lb. (4,80-5,53 kg) load. o 351 cu. in. (5.8 liter) engines:2.49 in. (63,2 mm)length with a 18.2-20.2 lb. (8,25-9,16 kg) load. If the spring tension is not within specifications, and/or spring is worn or damaged, replace the spring. Check the relief valve piston for scores and free operation in bore. The internal componentsof the oil pumpare not serviced. if any component is out of specifications, the pumpassembly must be replaced. Assembly 1. Install relief valve, spring and relief valve plug in oil pump housing. Press plug inward until it seats, then install the cotter pin. 2. install outer rotor and rotor shaft in housing. Be sure that identification markon outer rotor is on the sameside as identification mark on inner rotor. Fill the housing with engine oil for priming purposes. 3. Install the cover plate and tighten the four screwsto 72-120in. Ibs. (8,1-13,6 N-m). Installation 1. Primeoil pumpby filling pumpinlet port with engine oil. Rotate pumpshaft to distribute oil within pumpbody. 2. Position intermediate driveshaft into distributor socket. With ,,;eat firmly seated in distributor socket, the stop on the shaft should touch roof of crankcase. Removeshaft and position stop as necessary.

© DR1841

EEl [~ 3. With stop properly positioned, insert intermediate driveshaft (~) into oil pump. install pumpand shaft as an assembly. Do not attemptto force pump into position if it will not seat readily. The drive hex maybe misaligned with the distributor shaft. Rotate intermediate driveshaft to align. Tighten oil pump mountingscrews (~) to 22-32 ft. Ibs. (30-43 N-m). ~] 4. Clean and install oil pumpinter tube and screen assembly using a new gasket. Tighten mounting screws © to 10-15 ft. Ibs. (14-20 N-m). Attach oil pumptube to engine block and tighten nut @to 22-32 ft. Ibs. (30-43 N-m). 5. install oil installation.

DR4590

pan and related parts as outlined under Oil Pan

Crankshaft Rear Oil Seal All models have a one piece crankshaft rear oil seal. complete seal is replaced without removing crankshaft.

This

Removal 1. Removeengine from boat by following Removaland installation section.

procedures in Engine DR4591

2. Removestarter motor. 3. Removeflywheel housing, coupling, flywheel and cover.

#

FRONT OF ENGINE

4. Using a sharp awl, punch one hole into the seal metal surface between the lip and engine bmock. 5. Screw in the threaded end of Snide HammerTool "I-/7L-9533-B or equivalent. Use the slide hammerto remove the seal. Use caution to avoid scratching or damagingthe oil seal surface. installation 1. Lubricate newseal with engine oil. ~] 2. 302 cu, in. (5.0 liter) engines:Position oil seal with seal lip facing forward on rear Oil Seal Installer T82L-6701-Aor equivalent. Position seal and tool on rear of the engine. Alternate bolt tightening to properly seat seal The rear face of seal must be within 0.005 in. (0,127 ram) of rear face of block. EEl 351 cu. in. (5.8 liter} engines: Start seal with seal lip facing forward and install it with the rear Oil Seal Replacer tool T65P6701-Aor equivalent. Keeptool straight with centerline of crankshaft and instalJ seal until tool contacts cylinder block surface.

DR1860

FRONT OF ENGINE

5-18

DR25~3 Engme/er~g

[~ Removethe tool and inspect the seal to ensure it damagedduring installation.

was not

3. anstall flywhee~ cover, flywheel, coupling and housing. 4o install starter motor. 5. install engine into boat following procedures in Engine Removal and installation section.

Valve RockerArmand Cover Removal 1. Disconnect spark plug wires from spark plugs by grasping, twisting and pulMing molded cap only, using Spark Plug Wire Remover"F74P-6666-A or equivalent. 2. Removethe exhaust manifold. 3= Removethe valve rocker arm cover(s). 4. Removevalve rocker arm bolt (~, fulcrum ®,rocker arm ~) and fulcrum guide ®. inspection - Rocker Arm if the pad at valve end of rocker arm has a groovedradius, repmace rocker arm. Do not attempt to true this surface by grinding. inspection - PushRod Check ends of push rods for nicks, grooves, roughness or excessive wear. "The push rods can be visually checkedfor straightness while they are installed in the engine by rotating them with the valve closed. ’They also can be checked with a dial indicator for a maximum irunout of 0.015 ill. (0,38 ram). if the pushrod is visibly bent, it should be replaced.

1. Apply Ford Multi-Purpose Grease DOAZ-19584-AAor equivaIlent to the top of the valve stems, the rocker arm and fulcrum seats, and upper ,ends of push rods.

DR25~

NoteJ Thefollowing procedure will placethe lifter on a flat of the camshaft,not on a portion of the lobe to allow easyinstallation of the rocker arms. [~ 2. Position No. 1 piston on TDCat the end of compression stroke, Position @,andinstall rocker arm, fulcrum, fulcrum guide andbolt on the following valves: ¯ No. 1 Intake, No. 1 Exhaust ¯ No. 4 Intake, No. 3 Exhaust ¯ No. 8 Intake, No. 7 Exhaust r~ 3. Rotate crankshaft to Position ®, 180° from TDC(~, and (~ TDC ° from (~) install rocker arm, fulcrum, funcrumguide andbolt on the following ® 180 © 270° from ~) valves: ® No. 3 Intake, No. 2 Exhaust ¯ No. 7 Intake, No. 6 Exhaust [~ 4. Rotate crankshaft to Position ©, 270° from Position @,and install rocker arm,fulcrum, andbolt on the following valves: ¯ No. 2 Intake, No. 4 Exhaust ¯ No. 5 Intake, No. 5 Exhaust ¯ No. 6 Intake, No. 8 Exhaust 5. Be sure that the fulcrumbaseis inserted in its slot on the cylinder headbeforetightening the fulcrumbolts. Tightenfulcrumbolt to 18-25ft. Ibs. (24-34 N.m).Check valveclearancefollowing proceduresunder Valve ClearanceCheckingProcedures 6. Clean and inspect gasket surfaces of engine block and valve cover(s). Rnspectvalve cover gasket sealing surface(s) for damage anddistortion due to overtighting of bolts. Place a newgasketin cover(s), makingsure that tabs of gasket engagenotchesprovided in cover(s). 7. Position cover(s) on cylinder headgasketsurface(s). Make gasketseatsevenlyall aroundhead.Install bolts. Thecoveris tightenedin two steps. Tighten bolts to 36--60in. Ibs. (4-6 N.m). Wait two minutes, then tighten bolts to the samespecifications. If the starboard cover wasremoved,install PCVvalve. 8. Install exhaustmanifold. Connectspark plug wires. Start engine and checkfor leaks.

® DR1845

Valve Clearance Check Thevalve arrangement is on the port bankis E-I-E-I-E-I-E-I andon the starboardbankis I-E-I-E-I-E-I-E. Valvestemto valve rocker armclearanceshouldbe within specifications with the hydrauliclifter completelycollapsed.Repeated valve reconditioningoperations(valve and/orvalve seat refacing) or valve seat recession wear causedby (extended use) will decreasethe clearanceto the point that, if not compensated for, the hydraulic valve lifter will ceaseto function andthe valve will be held open.

Notej Theuse of positive stop rocker armbolts eliminates the needto adjust the; valve clearance. However,to obtain the specilied valve clearance,it is importantthat all valve components be in a serviceablecondition andinstalled andtightened properly. To determine whether newservice parts are necessary, makethe following check: ~_~1. Removethe PURPLE wire from the "1" terminal of the starter assist solenoidso the enginedoesnot start. Install an auxiliary starter switch. Crankthe engine with the ignition switch OFFuntil the No. 1 piston is on TDCafter the compression stroke. I~ 2. With the crankshaftin the positions designatedin Steps2, 3 and 4, position the Hydraulic Lifter Compressor Tool T71P-6513-B @or equivalent on the rocker arm. Slowly apply pressureto bleed downthe hydraulic lifter until the plungeris completelyboltomed. Holdthe lifter in this position andcheckthe available clearance betweenthe rocker armandthe valve stemtip with a feeler’ gauge DR1845

[3~ 3. With the No. 1 piston onTDC at the end of the compression (~)TDC ® 180° from (~) stroke as shownin Position @,checkthe following valves: ° from (~) © 270 ¯ No. 1 Intake, No. 1 Exhaust ® No. 4 Intake, No. 3 Exhaust ® No. 8 Intake, No. 7 Exhaust [~ 4. After checkingthe spacingon these valves, rotate the crank.,;haft to Position (~, 180° from TDC@, then checkthe following vamves: ® No. 3 Intake, No. 2 Exhaust ® No. 7 Intake, No. 6 Exhaust

l.-’~in~

~ Safety Related

5-21

L__U5o After checkingspacingon these valves, rotate the crankshaft to Position @,270° from Position @,andcheckthe following valves: ¯ No. 2 Intake, No. 4 Exhaust ® No. 5 Intake, No. 5 Exhaust ® No. 6 Intake, No. 8 Exhaust ClearanceSpecifications: 5.0 Modems Allowable: 0.071-0.193in. (1,8-4,9 ram) Desirable: 0.096-0.165in. (2,4-4,2 mm)

~) TDC ° from (~) ® 180 @ 270° from ~)

5.8 Models Allowable: 0.098--0.198in. (2,5--5,0 mm) Desirable: 0.123--0.173in. (3,1-4,4 ram) Valve Lifter Thefollowing procedureis applicablefor removingoneor all of the valve lifters. Beforereplacinga hydraulic valvelifter for noisyoperation, be sure the noise is not causedby impropervalve clearance or by worn rocker armsand/or push rods. Dirt, gumor varnish depositsandair bubblesin the lubricating oil cancausehydraulic valve lifter failure or malfunction. Dirt, gumand varnish can keep a check valve from seating and causea loss of hydraulic pressure. An openvalve disc will cause the plungerto force oil backinto valve lifter reservoir during time pushrod is beinglifted to force valve fromits seat. Air bubblesin the lubricating systemcan be causedby too high or too low an oil level. Air mayalso be drawninto the lubricating systemthroughan openingin a damaged oil pick-up tube. Air in an oil lifter cancausea loss of pressureto lifter. Removal 1. Remove intake manifold and related parts following procedures under intake Manifold. 2. Removethe valve rocker arm covers. Loosenthe rocker arm bolts andturn rocker armsto one side. 3. Remove the push rods in sequenceso they can be nstalled in their original positions. 4. Using Hydraulic TappetPuller T70L-6500-A or equivalent, removelifters andplacethemin a rack so that they canby installed in their original bores. 5-22

Engine/eng

Cleaning Thoroughly clean all the parts in cleaning solvent and wipe them with a clean, lint-free cloth. inspection inspect the parts and discard the entire lifter assemblyif any part showspitting, scoring, galling or evidence of non-rotation. Replace entire assemblyif plunger is not free in the body. Checkfor freeness of operation by pressing downon the push rod cup. Thelifters can also be checkedwith a hydraulic tester to test leak-down rate. Follow tester manufacturer’s instructions to perform test. Installation 1. Clean outside of valve lifters. Lifters and bores are to be lubricated with specified engine oil before installation. Install lifters in their original bores. Checkany newlifter for free fit in bore to which it has been installed. 2. Apply Ford Multi-Purpose Grease DOAZ-19584-AAor equivalent to valve stem tips and push rod ends. Install push rods in original positions. ,’3. Lubricate rocker arms and fulcrum seats with Ford MultiPurpose Grease DOAZ-19584-AAor equivalent. 4. Position the rocker arms over the push rods and tighten the bolts following the procedure under Valve Rocker Arm Installation. Adjust valve clearance following procedure under Valve Clearance Check. 5. install rocker arm covers following Armand Cover Installation.

procedure under Rocker

6. Install intake manifold and related parts following the procedures under intake Nianifold.

Core Plugs Removal To removea large core plug, drill a 1/2 in. (12,7 mm)hole in center of plug and remove with an Clutch Pilot Bearing Puller Tool T59L-100-Band T58L-101-Aor pry it out with a large drift punch. Ona small core plug, drill a 1/4 in. (6,37 ram) hole in center of plug and pry it out with a small pin punch. Cleanand inspect plug bore. Prior to installing a core plug, plug bore should be inspected for any damagethat would interfere with proper sealing of plug. if bore is damaged it will be necessaryto true surface by bori:ng for the next specified oversize plug. Oversize (OS} plugs are identified by OSstampedin flat located on the cup side of plug.

Ughtly coat plug and/or bore with an oil resistant (oil galley) water-resistant (cooling jacket) sealer, and install it following procedure for cup-type or expansion-type below: installation - Cup-Type ~] Cup-type core plugs (~) are installed with flanged edge outward. The maximumdiameter of this plug is located at outer edgeof flange. The flange on cup-type plugs flare outward with largest diameter at outer (sealing) edge it is imperative to push plug into machinedbore by using a properly designed tool Under no circumstances is plug to be driven into bore using a tool that contacts flange. This method will damagethe sealing edge and will result in leakage and/or plug blow out.

DR1847

The flanged (trailing) edge must be below chamfered edge of bore to effectively seal plugged bore. If core plug replacing too{ has a depth seating surface, do not seat tool against a non-machined(casting) surface. Installation - Expansion-Type DR1848

~-~ Expansion-type core plugs <~) are installed with flanged edge inward. The maximumdiameter of this plug is located at base of flange with flange (~) flaring inward. It is imperative to pushor drive plug into machinedbore using a properly designed tool. Under no circumstances is plug to be driven using a tool that contacts crowned portion of plug. This method will expand plug prior to installation and may damage plug and/or plug bore. Wheninstalling plug, the trailing (maximumdiameter) must below chamfered edge of bore to effectively seal bore. if core replacing tool has a depth seating surface, do not seat tool against a non-machined(casting) surface.

Diagnosis and Testing Camshaft Lobe Uft Checklift ofeachlobein consecutive order, and make a note of the readings. 1. Removevalve rocker arm cover. 2. Removevalve rocker arm. Install a solid, tappet-type push rod in push rod bore of camshaft lobe to be checked, or use the adapter for ball end push rods.

5-24

E~Jne~

E~ 3. Makesure push rod (~) is seated against camshaftlobe. Install a dial indicator so that actuatingpoint ® of indicator is in pushrod socket(er the indicator ball socketadapteris on endof the push rod) and in sameplane as push rod movement. 4. Removespark plugs. 5. Connectan auxiliary starter switch in starting circuit. Crank enginewith ignition switch OFF.Bump crankshaft over until lifter is on basecircle of camshaft lobe. At this point, pushrod will be in its lowestposition. 6. Zerodial indicator. Continueto rotate crankshaftslowly until pushrod is in fully raised position. 7. Compare total lift tions:

recordedon dial indicator with specifica-

302cu. in. (5.0 liter) and351cu. in. (5.8 liter): Intake- 0.278in. (’7,061 ram) Exhaust- 0.283 in. (7,188 ram} Maximum Allowable Loss - 0.005 in. (0,13 ram) 8. To checkaccuracyof original indicator reading, continue to rotate crankshaftuntil indicator readsZERO. If lift on any lobe is belowspecified wearlimits, camshaftandvalve lifters operating on the wornlobe(s) mustbe replacedas well as any lifter showing pitting or havinga contact face wornflat or concave. 9. Remove dial indicator andauxiliary starter switch, install rocker arm. NOTE: Do not rotate crankshaft until hydraulic liftere; have had a chanceto bleed down. To do otherwise maycauseserious valve damage.Manuallybleeding downlifters will reducewaiting time, 10. Install the valve rocker armcover. 11. Install sparkplugs. Compression Test 1. Be sure crankcaseoil is at proper level and of correct viscosity. Makesure that battery is properly charged. Operate engine for a minimum of 30 minutesat 1200RPM,or until engine is at normaloperatingtemperature.Turnignition switch off; place the shift control in NEUTRAL, and removethe shorting balr from the double wire SPOUT connector at ignition coil. 2. Remove all spark plugs. 3. install a compression gaugein No. 1 cylinder.

e,~,,o ,~ Safety Related

5-25

DR1849

L~ 4. install an auxiliary starter switch in starting circuit. Using auxiliary starter switch, crank engine (with ignition switch OFF) at Jeast five compression strokes and record highest reading. Note approximate number of compression strokes required to obtain highest reading. 5. Repeat test on each cylinder. Crank engine same number of compressionstrokes as was required to obtain highest reading on No. 1 cylinder. Test Conclusion The indicated compression pressures are considered normal if Jowest reading cylinder is within 75%of the highest. Refer to the following example: Highest Reading: 140 PSI (8703 kPa) 75%: 105 PSi (5027 kPa) Jn this example, any cylinder reading less than 105 PSi (5027 kPa) indicates an improperly seated vaRve, or worn or broken piston rings. af one or more cylinders read low, squirt approximately one tablespoon of engine oil on top of the pistons in low reading cyJinders. Repeat compression pressure check on these cyl|nders. 1. Jf compressionimproves considerabJy, piston rings are at fault. 2. If compressiondoes not improve, valves are sticking or seating poorly or valve guides are leaking. 3. if two adjacent cylinders indicate low compression pressures and squirting oil on pistons does not increase compression, the cause may be a cylinder head gasket leak between cylinders. Engine oil and/Or coolant in the cylinders could result from this problem.

Positive Closed-TypeVentilation System A malfunctioning closed crankcase ventilation system may be indicated by loping or rough engine idle. Do not attempt to compensatefor this idle condition by disconnecting the crankcase ventilation system and making carburetor adjustments. The removalof the crankcaseventilation systemfrom the engine wii| adversely affect fuel economy and engine ventilation with resultant shortening of engine life. To determine whether loping or rough idle condition is caused by a malfunctioning crankcase ventilation system, perform the folJowing tests.

L~ Safety Related

5-26

1. RemovePCVvalve from its mounting, but leave vacuuminlet side connected to hose. If the valve is functioning properly and not plugged, a hissing noise will be heard as air passes through valve. A strong vacuumwill be felt whena finger is placed over valve inlet. Check for vacuum leaks in hose line and at all connections. 2. Reinstall PCVvalve, then removecrankcase air inlet hose at flame arrestor connection. Loosely hold a small piece of stiff paper (such as a 3 × 5 memocard or parts tag card) over opening at end of inlet hose. After a minute or so, (to allow crankcase pressure to lower) the piece of paper should be sucked against hose opening with a noticeable force.

RemovePCV valve from its mounting and shake it. A metallic clicking noise should be heard, indicating that valve parl;s are free, and not sticking. if ventilation systempassesthese two tests, it can be considered functionally OK,and no further service is required. If it fails either test, replace PCVvalve and repeat Engine idling Test. ff systemstill

does not pass test, perform the folmowing:

¯ Removeand clean crankcase filter valve grommet.

located under the PCV

o Clean ventiEation system hoses and all passages to induction system in accordance with established procedures. Servicing PCVValve 31588

Do not attempt to clean crankcaseventilation regulator valve, it should be replacecL Clean crankcase ventilation system connection(s} on intake manifold by probing with a fle×ible wire or bottle brush. CUeanhoses, tubes and associated hardware with a lowvolatility, petroleum-base solvent and dry with compressedair.

Front Engine Mounts Removal E~ ~ 1. Prior to removing a front mount, measure distance between large washer (~ and flat (~) on upper mount bracket. Record this dimension so mount can be correctly reassembled.

31582

E2-~ 2. Removethe top nut and washers from the mount. [3~ 3. Removethe two lag screws © and washers securing the mount.

Engine/eng

5-27

31580

~4. Lift enginewith 1500 lb. (680 kg) minimum capacity hoist to allow remova!of front mount. E~ 5. Removetwo mountbracket-to-block screws and lock washers @and removebracket. Disassembly ~] Hold mount bolt with a socket, and remove the two nuts and disassemble mount.

31578

Assembly ~-1 Place small washer® on the mountbolt and insert bolt up through mount. Install large washer ® and secure with nut @. Torqueto 60-75ft. Ibs. (81-102N.m). Installation E~ Fully seat front enginemountadjusting bolts into the front engine mount ®.

Dt~558

,~,CAUTION Bolt hole @is usedfor 5.8 liter blocks only, bolt hole O is for the 5.0 liter blocks only. Theenginewill be damaged if these positions are usedincorrectly. Note] The head of support screw and mating contact point on block mustbe free of paint. r’T] 2. Sprayboth mountbracket-to-blockscrewswith Loctite primer or equivalent and allow to air dry. Apply Loctite or equivalent to both screws. Attach bracket to engine with two screwsand washers. Tightenscrewsto 32---40ft. Ibs. (43-54N-m).

11983

E~ 3. Place a 0.005 in. (0.13 mm)feeler gaugebetweenthe engine block and the enginemountadjusting bolt. Adjust the engine mountadjustingbolt in or out until a resistanceis felt on the feeler gauge. 4. Mark the engine mountadjusting bolt head. Back the engine mountadjustingbolt out exactly onehalf (1/2) turn. [~ 4. Install upper inner nut and washer ® on mountassembly andplace bolt into bracket, then install top nut andwashers@. 5. Set height adjustment,

]/~ Safety Related

refer

DR4529A

to Height Adjustment.

5-28

31577 Engine/eng

Height Adjustment Z~ 1. Lift enginewith a hoist capableof lifting at least 1500 lb. (B80 kg). Position engineat desired height. L6~ 2. To changeengine height, tighten or loosen nuts (~) and as required. EEl 3. After setting mount position, turn nut (~ up against underside of engine bracket and hold nut with a wrench. Tighten top nut (~ to 50-70 ft. lbs. (68-95 N.m). [~ Any large adjustments to engine height should be fok h)wed by a check of engine alignment. Failure to check alignment could result in rapid engine coupler failure.

High-Rise Exhaust Elbow Replacement Remova| [7~ 1. Loosen two clamps securing upper hose. Lubricate inside of hose ,with a soapy water solution. 2. Starboard Only: Removescrews securing ECA to high-rise elbow and set out of the way.

32696

[3 I~ 2. Removefour screws, flat washers and lock wa,shers mounting high-rise elbow. Use a soft hammerto free the elbow from the manifold,. Use a twisting motion to pull high-rise elbow from hose. Removeand discard the manifold gasket. JnstaJJation [!~] 1. Thoroughly clean manifold gasket surface ~). Apply Gasket Sealing Compoundto both sides of a new gasket and place it on the exhaust manifold. 32687

[~ 2. Lubricate the inside of the exhaust hose with a soapy water soUution, insert the high-rise elbow into the hose with a twisting motion, and push it into hose as far as it wilt go, 3. Position high-rise elbow on manifold. Install four screws, flat washersand lock washers. Tighten screws to 12-18 ft. Ibs. (16-24 N-m). Starboard Only: Attach ECAto high-rise elbow. 4. Slide clamps up onto hose and position them in the two surface channels. Tighten clamps securely. 32688

I~,,~o~/~0 ~ Safety Related

5-29

32689

32691

32692

32693

Exhaust Hose and Intermediate Pipe Replacement Removal [~ 1o Loosen four clamps ~) attaching clamps off the hose.

lower hose, and slide

~l 2. Lubricate inside of hose, top and bottom, with a soapy water solution, and slide hose down onto exhaust pipe. F~ 3. Loosen all clamps on upper hose. Removeintermediate pipe ® with a twisting motion. [~] 4. Slide upper hose off high-rise elbow. [~ 5. Slide lower hose off exhaust Y-pipe. |nstallation [-~ ~ Both the upper and lower hoses have a step in the inside diameter that must face the intermediate pipe. ~] 1. Lubricate inside diameter of lower hose with a soapy water solution. Slide it all the way onto the exhaust Y-pipe.

32695

[~ 2. Place four clamps on upper hose. Push hose all the way onto high-rise, elbow. Position clamps in channels at top of hose, and tighten clamps securely. F~ 3. Lubricate inside of upper hose. With a twisting motion, insert intermediate pipe (~) all the way into the upper hose and position it as shown. Do not attach the hose clamps at this time. 32366

E~ 4. Slide lower hose up until it equally overlaps the intermediate and exhaust pipes. ET~ 5. Slide two clamps © onto upper hose. Slide four remaining clamps (~) onto lower hose. Position clamps in channels and tighten securely.

Exhaust (Flapper) Valve Replacernent - SX Models Removal 6373

1. The exhaust valves are at the upper ends of the exhaust pipes. Removeadaptor pipes and lower exhaust hoses. ES~2. Using a small drift or punch ~), push the exhaust valve pin (~) out of each exhaust pipe. [~ [~ 3. Remove pin and valve. ings.

Push out two rubber bush-

installation 1. Apply Scotch Grip Rubber Adhesive to two new rubber bushings and push into each exhaust pipe.

6375A

~1~ ~ 2. Lightly lubricate exhaust valve pin with oil. Position valve in each exhaust pipe with long side of valve down. Pushpin through bushing and exhaust vamveuntil flush with both sides of pipe. Check exhaust valve for freedom of movement. if the valve is not positioned properly (long mip down}, it will restrict exhaust flow and fail to prevent water from backing up into exhaust system. Boat performance could be adversely affected, and major powerhead damagecould occur. 3. install

6376

exhaust hoses and adaptor pipes.

6377

Engine/eng

5-31

.,8

Engine Coupler Replacement - SX Models Removal if coupler is being replaced due to coupler failure (rubber hub of splined hub), check engine alignment after installing new coupler. 1. Removeengine from boat following instructions Remova|and mnstructions, in this manualo

in Engine

2. Cut tie strap holding flywheel housing drain hose to starter motor, then remove starter. Removesmall screws along forward edge of bellhousing plate. EEl 3. Unscrew outer nut on ground stud, and take off lock washer and electrical leads. Removeinner nut, lock washer and washer. Removesimilar ground stud hardware on opposite side of bnock. 4. Removepower steering cooler. Unscrew remaining flywheel housing bolts, lock washers and washers. Note position of clamps so they can be installed in original position. [~] 5. Loosen belihousing engine.

with a soft

hammer, and pull

off

6675

6. Unscrewsix nuts and lock washers, then pult coupler off flywheel. installation 1. Slide coupler onto crankshaft studs. Install lock washers and nuts. Use a crowfoot wrenchand tighten nuts to 40-45 ft. Ibs. (54-61 N-m). 6710

67tZA

~’6--~ 2. Install flywheel housing. Place clampsin their original positions and attach power steering cooler. Tighten screws to 28-36 ft. Ibs. (38-49 N-m). L~ 3. Place washer, lock washer and nut on ground stud. Tighten inner nut to a torque of 20-25 ft. lbs. (27-34 N.m). Attach electrical leads to ground stud. install lock washer end tighten outer nut securely. Install ground stud hardwareon opposite side of block. L~ 4. install small screws along forward edge of bellhousing plate and tighten to 60-84 in. Ibs. (6,7-9,5 N-m). Install starter motor and tighten screws to 24-30 ft. Ibs. (33-41 N-m). Attach flywheel housing drain hose to starter motor with a tie strap. 5. Install engine in boat following instructions in Engine Removal and Installation in this manual.

6711A

TorqueSpecifications- All Models The following specifications

are for screw sizes not shownotherwise:

SCREW SiZE

FT. LBS

iN, LBS.

N-m

No. 6 No. 10 No. 12 1/4 %s %

2-3 3-4 5- 7 10 - 12 18 - 20

7- 10 25-35 35-45 60 - 80 120 - 140 220 - 240

0,8- 1 3-4 4-5 7- 9 14- 16 24- 27

Use a reliable torque wrenchto tighten the parts listed to prevent straining or distorting the parts or possibly damagingthe threads. These specifications are for clean threads only. Dirty threads produce friction which prevents accurate measurement of tightness. It is important that these torque specifications be strictly observed. Overtightening to any extent maydamagethreads, thus preventing proper torque from being obtained, requiring replacement or repair of the damagedpart.

Adaptor- Oil Pressure Sender Alternator- Bracket to Pump Camshaft Sprocket Circulating Pump Cover, Flywheel Housing Cover Plate, Oil Pump Cylinder Block Cover Distributor Clamp Exhaust Elbow Exhaust Manifold Fitting, Oil Withdrawal Tube Flywheel Bellhousing Flywheel Cover Front Mount to Block Fuel Pump Intake Manifold Oil Inlet Tube-to-Pump Oil Inlet "PdbeBracket Oil Pan (114 x 20) Oil Pan (5116 x 18) Power Steering PumpBracket Pulley, Crankshaft Pulley, Circulating Pump Rocker Arm Rocker Arm Cover Starter Motor Starter Motor 8racket

10-14 18-20 40-45 12-18

6O-84 72-120

12-18 17-25 12-18 20-26 15-18 28-36 60-84 32-40 18-20 23-25 10-15 22-32 9-11 9-11 26-30 22-32 14-20 18-25 24-30 16-19

5-34

36-60

14-19 24-27 55-61 17-24 6,7-9,5 8-16 17-24 23-34 16-24 27-35 20-24 38-49 6,7-9,5 43-54 24-27 31-34 14-20 30-43 12-15 12-15 35-41 30-43 19-27 24-34 4-6 33-41 22-26

Engine/eng

TorqueSpecifications- (Cont.) IFr. US.JCIN.LBS. 1

Raw-water PumpBracket Thermostat Housing Throttle Body Upper Manifold Water Outlet Housing

Connecting Rod 302/5.0 351/5.8 Coupler, Engine Exhaust Manifold Flame Arrestor Front Mount (top) Vibration Damper Withdrawal Tube to Fitting

-

17-24 16-22 16-24 16-24 14-20

19-24 40-45 40-45 20-26

30-40

26-33 54-61 54-61 27-35 3,4-4,5 68-95 95-122 20-24

50-70 70-90 15-18

Cylinder" Head(302/5.0) Step 1 Step 2 Step 3 Cylinder Head(351/5.8) Step 1 Step 2 Main Bearing Cap 302/5.0 351/5.8 Front Mount

E,~,/~,

12-18 12-16 12-18 12-18 10-15

25-35 33,8-47,4 45-55 61,0-74,5 Tighten an additional 85°- 95° (1/4 turn) 95-105 105-112

129-143 143-151

-

60-70 95-105 60-75

81-95 129-142 81-102

Flywheel and Coupler

10-15

-

Oil Filter Sender, Oil Pressure Sender, Water Temperature Spark Plugs

One"Turn 10-14 18-22 10-15

After Contact 14-19 24-30 1 4-20

5-35

14-20

Engine Specifications 1. GeneralSpecifications Type - No. of Cylinder ............................. Bore and Stroke - 302/5.0 .......................... Bore and Stroke - 351/5.8 .......................... Piston Displacement - 302/5.0 ....................... Piston Displacement- 351/5.8 ....................... Cylinder No. (front to rear - starboard) ................ Cylinder No. (front to rear - port) .................... Firing Order .................................... Compression Ratio - 302/5.0 ........................ Compression Ratio - 351/5.8 ........................ Fuel System - 302/5.0 ............................. Fuel System - 351/5.8 ............................. Thermostat Opens at ............................. Full Throttle Operating Range - 5.0/5.8 ................

90° V - 8 4.00 in. x 3.00 in. 4.00 in. x 3.50 in. 302Cu. In. (5.0 Litre) 351Cu. In. (5.8 Litre) 1- 2- 3 - 4 5- 6- 7- 8 1 - 3- 7- 2- 6- 5- 4- 8 8.5:1 8.8:1 Electric pump Electric pump 160° F 4200-4600 RPM

2. Engine Dimensions, Fits and Adjustments Cylinder Head: Combustion ChamberVolume (cc) - 302/5.0 ......... Combustion Chamber Volume (cc) - 351/5.8 ......... Valve Guide Bore Diameter ...................... Valve Seat Width intake and Exhaust ........................ Valve Seat Angle - Intake and Exhaust ............. Valve Seat Runout - Maximum ................... Valve Arrangement (Front to Rear) Right .................................. Left ................................... Gasket Surface Flatness ........................ Gasket Surface Finish

RMS* .....................

60.6-63.6 63.4-66.4 0.3433-0.3443 in. 0.060-0.080 in. ° 45 0.0020 in. I-E-I-E-I-E-I-E E-I-E-I-E-I-E-i 0.003 inch in any 6 inches or 0.006 inch overall 60-150

* RMS- Root Mean Square Valve Rocker Arms, Push Rod and Ufters: Rocker Arm Lift Ratio .......................... Valve Push Rod Runout- Maximum ............... Hydraulic Lifter Leakdown Rate ...........................

Hydraulic Lifter Standard Diameter ........................ Clearance to Bore ......................... Service Limit ............................

1.61:1 0.015 in. 5-50 seconds maximum measuredat V~ein. plunger travel with 50 Ibs. load and leak down fluid in tappet 0.8740-0.8745in. 0.0007-0.0027in. 0.005 in.

EngineSpecifications Cont. Valve Rocker Arms, PushRod and Lifters Cent: Hydraulic Lifter Collapsed Gap 302/5.0 Allowable ................................ Desired .................................. 351/5.8 Allowable ................................ Desired .................................. Valves: Valve Stern Diameter Intake .................................. Exhaust ................................ Valve Face Angle .............................. Valve Stem to Valve Guide Clearance Intake .................................. Exhaust ................................ Wear Limit .............................. Valve Head Diameter Intake - 5.0/5.8 ........................... Exhaust - 5.0 ............................ Exhaust. - 5.8 ............................ Valve Face Runout (Maximum) ................... Valve Spring Free Length - Approximate intake .................................. Exhaust: ................................ Valve Spring Out-of-Square Maximum ............................... Valve Spring Pressure - Lbs. at Specified Length Intake .................................. Intake .................................. Exhaust ................................ Exhaust: ................................ Service Limit ............................ Valve Spring AssembledHeight - Pad to Retainer Intake .................................. Exhaust ................................

0.071-0.193 in. 0.096-0.165 in. 0.098-0.1913in. 0.123-0.173in.

0.34160.3423 in. 0.3411-0.3418in. °44 0.0010-0.0027in. 0.0015-0.0032in. 0.0055 in. 1.837-1.847in. 1.536-1.546in. 1.837-1.847in. 0.0020 in. 2.056 in. 1.877 in. ~’~ (0.078)iin. 78+4 Ibs. @1.78 in. 204-+10Ib.¢L @1.15 in. 75-+4 Ibs. @1.33 in. 205-10 Ibm;. @1.15 10% Pressure Loss @Spec. Length 1.78 in. 1.60 in.

Camshaft and Bearings: Camshaft No. No. No. No. No.

Journal Diameter Standard 1 Bearing ............................ 2 Bearing ............................ 3 Bearing ............................ 4 Bearing ............................ 5 Bearing ............................

2.0805-2.0815in. 2.0655-2.0665in. 2.0505-2.05115in. 2.0355-2.03:65in. 2.0205-2.02’15in.

Engine Specifications Cont.

7

Camshaft and Bearings Cont: Camshaft Journal to Bearing Clearance ............ Camshaft End Play ............................ Camshaft Lobe Lift 302/5.0 Intake .................................. Exhaust ................................ 351/5.8 Intake .................................. Exhaust ................................ Maximum Allowable Lobe Lift Loss ............... Bearing Inside Diameter Bearing No. 1 ............................ Bearing No. 2 ............................ Bearing No. 3 ............................ Bearing No. 4 ............................ Bearing No. 5 ............................ Camshaft Journal Maximum Runout TJ.R.** .................. Camshaft Bearing Location No. 1 Bearing ............................ Timing Chain Deflection - Maximum...............

0.001-0.003in. Service Limit - 0.006 in. 0.001-0.007in. Service Limit - 0.009 in. 0.2600 in. 0.2780 in. 0.2780 in. 0.2830 in. 0.005 in. 2.0825-2.0835in. 2.0675-2.0685in. 2°0525-2.0535in. 2.0375-2.0385in. 2.0225-2.0235in. 0.005 in. 0.0050-0.0200 in.* 0.500 in.

* Distance in inches that the front edge of the bearing is installed toward the rear from the front face of the cylinder block. ~’* Total Indicated Reading Crankshaft Main Bearings: Journal Clearance 302/5.0- No. 1 Bearing Desired ................................. Allowable ............................... 302/5.0 -Alt others Desired ................................. Allowable ............................... 351/5.8 Desired ................................. Allowable ............................... Wall Thickness 302/5.0- No. 1 Bearing ....................... All Others ............................... 351/5.8- No. 1 Bearing ....................... All Others ...............................

0.0001-0.0015in. 0.0001-0.0020in. 0.0005-0.0015in. 0.0005-0.0024 in. 0.0008-0.0015 in. 0.0008-0.0026 in. 0.0961-0.0966 in. 0.0957-0.0962in. 0.0957-0.0960in. 0.0957-0.0962in.

EngineSpecifications Cont, Crankshaft and Fiywheeh Main Bearing Journal Diameter 302/5.0 ................................. 351/5.8 ................................. Main Bearing Journal Out-of-Round Max ........... Maximum Runout T.I.R. ~ .................. Taper Limit .................................. Surface Finish Maximum ....................... Connecting Rod Journal Diameter 302/5.0 ................................. 351/5.8 ................................. Connecting Rod Journal Out-of-Round Maximum ............................... Connecting Rod Journal Taper Maximum ............................... Surface Finish Limit ........................... Thrust Bearing Journal Length ................... Main Bearing Journal Thrust Face Runout Limit ........................ Face Finish .............................. Crankshaft to Rear Face of Block Runout T.i.R.** Maximum ............................... Crankshaft End Play Clearance ...................

2.2482-2.2490in. 2.9994-3.0002in. 0.0006 in. 0.002 0.0004 per in. 12 RMS 2.1228-2.1236in. 2.3103-2.3:111in. 0.0006 per in. 0.0006pea" in. 12 RMS 1.137-1.139in. 0.001 25 Front 20 Rear RMS 0.005 in. 0.004-0.008in. Service Limit- 0.012 in. max.

*~ Total Indicated Reading Connecting Rod: Piston Pin Bore I.D. - Standard ................... Bearing Bore Diameter 302/5.0 ................................. 351/5.8 ................................. Bearing Bore Out-of Round and Taper .............. Connecting Rod Length - Center to Center 302/5.0 ................................. 351/5.8 .................................. Twist Total Difference - Maximum.................. Bend Total Difference - Maximum.................. Rod Assembled to Crankshaft Side Clearance ............................ Pin, bushing and crankshaft bearing bore must be parallel, and in the samevertical plane, within the specified total difference at ends of an 8-inch long bar measured 4 inches on each side of rod.

0.9096-0.9112in. 2.2390-2.2:398in. 2.4265-2.4,273in. 0.0004 in. 5.0885-5.0915in. 5.9545-5.9575in. 0.024 in. ~ 0.012 in. 0.010-0.020in. Service Limit- 0.023 in.

Engine

Specifications

Cont.

Connecting Rod Bearings: Bearing to Crankshaft Clearance Allowable ............................... Desired ................................. Wall Thickness - Standard .................. 0.002 Undersize ..........................

0.0008-0.0025in. 0.0008-0.0015in. 0.0572-0.0577in. 0.0582-0.0587in.

Pistons: Piston Diameter* Coded Red 302/5.0 ................................. 351/5.8 ................................. Coded Blue 302/5.0 ................................. 351/5.8 ................................. 0.003 Oversize 302/5.0 ................................. 351/5.8 ................................. Piston to Cylinder Bore Clearance ................. Piston Pin Bore Diameter ....................... Ring Groove Width, Compression 302/5.0 Top .................................... Bottom ................................. Oil Ring ................................ 351/5.8 Top .................................... Bottom ................................. Oil Ring ................................

3.9984-3.9990in. 3.9978-3.9984in. 3.9996-4.0002in. 3.9990-3.9960in. 4.0020-4.0026in. 4.0014-4.0020in. 0.0018-0.0026in. 0.9124-0.9127in. 0.060-0.061 in. 0.060-0.061in. 0.1587-0.1597in. 0.080-0.081in. 0.080-0.081 in. 0.1880-0.1890in.

* Measuredat the piston pin bore centerline at 90° to the pin Piston Pit{: Piston Pin diameter - Standard ................... 0.001 Oversize ........................... 0.002 Oversize ........................... Piston Pin Length ............................. Piston Pin to Piston Clearance 302/5.0 ................................. 351/5.8 ................................. Piston Pin to Connecting Rod Bushing Clearance .....

0.9120-09123in. 0.9130-0.9133 in. 0.9140-0.9143 in. 3.010-3.040 in. 0.0002-0.0004 in. 0.0003-0.0005in. Service Limit - 0.0008 in. interference Fit

Engine

Specifications

Cont

........... ~lillf~_

_ _.

PistonRings: 302/5.0 Top CompressionRing Width ................ Bottom CompressionRing Width ............. 351/5.8 Top CompressionRing Width ................ Bottom CompressionRing Width ............. Top CompressionRing Side Clearance ............. Bottom CompressionRing Side Clearance .......... Service Limit ................................. Oil Ring Side Clearance ........................ Top Compression Ring Gap ...................... Bottom Compression Ring Gap ................... Oil Ring (Steel Rail) Gap........................

0.0577-0.0587in. 0.0577-0.0587in. 0.077-0.078in. 0.077-0.078in. 0.002-0.004in. 0.002-0.004in. 0.002 max. increase in total clearance Snug 0.010-0.020in. 0.010-0.020in. 0.015-0.055in,

CylinderBlock: Cylinder Bore Diameter 302/5.0 ................................. 351/5.8 ................................. MaximumOut-of-Round ........................ MaximumTaper .............................. Crankshaft to Rear Faceof Block Runout T.I.R. Maximum.......................... Lifter Bore Diameter ........................... Main Bearing Bore Diameter 302/5.0 ................................. 351/5.8 ................................. Distributor Shaft Bearing Bore Diameter 302/5.0 ................................. 351/5.8 ................................. HeadGasket Surface Flatness .................... HeadGasket: Surface Finish RMS**................ Cylinder Bore Surface Finish RMS**...............

4.0004-4.0052 in. 4.0000-4.0048 in. 0.0015in. ServiceLimit - 0.005in. 0.001in. ServiceLimit - 0.010in. 0.005in. 0.8752-0.8767 in. 2.4412-2.4420 in. 3.1922-3.1930 in. 0.4525-0.~1541 in. 0.5155-0.5171 in. 0.003in. in any6 in. or 0.006in. overaln 60-150 18-38

** RMS- Root MeanSquare Off Pump: Relief Valve :Spring Tension(Lbs. @Specified Length) 302/5.0 ................................. 351/5.8 ................................. Driveshaft to HousingBearing Clearance ........... Relief Valve Clearance .......................... Rotor Assembly End Clearance ................... Outer Raceto HousingClearance(Radial) ...........

[email protected]. [email protected] in. 0.0015-0.0030 in. 0.0015-0.0030 in. 0.001-0.004in. 0.001-0.013in.

NOTES

5-42

Section 6 7.4, 8.2 GL, Gi andGSi

Table of Contents Camshaft ................................................. Camshaft Lobe Lift, Measuring ............................... Circulating Pump........................................... Crankshaft ................................................ Cylinder Block ............................................. Cylinder Head ............................................... Engine Specifications ....................................... Exhaust Hose and Intermediate Pipe Replacement............. Exhaust Manifold Replacement ................................ Front Engine Mount Replacement ............................ General Motors Tools ......................................... High-Rise Exhaust Elbow Replacement ....................... Intake Manifold .............................................. Lubrication System ......................................... Oil Pan ................................................... Oil Pump............. . ..................................... Oil Seal Replacement, Rear Main Bearing .............. " ....... Piston, Ring and Connecting Rod ........................... RemoteEngine Oil Filter .................................... Timing Chain, Cover and Seal ................................ Torque Specifications ....................................... Valve Lifter, Hydraulic ......................................... Valve Spring and Seal Repair ..................................

6-16 6-21 6-32 6-23 6-30 6-9 6-37 6-36 6-5 6-33 6-2 6-34 6-3 6-18 6-19 6-20 6-22 6-26 6-19 8-14 6-40 6-6 6-8

Safety Warnings Beforeworkingon anypart of the engine,readthe section called Safety at the endof this manual. Unlessinstructed otherwise,alwaysdisconnectthe battery cablesfrom the battery beforeworkingon electrical systemto preventpossiblesparksor arcing in the engine compartment. Before starting engine after repair or maintenance procedures,always make sure enginecompartment is free of fuel vaporsto preventpossiblefire andexplosion. Whenworkingon an enginethat is runningor being cranked,use extremecare to avoidgetting hands,fingers or clothingcaug;htin the alternator, powersteering pump,raw-waterpumpand circulating pumpbelts, pulleys andother moving parts.

/

Genera/Motors Tools Part Number

item Air Line Adaptor .............................. Bearing Puller Set .............................. Camshaft Lobe Lift Indicator ...................... Carbon Remover ............................... Dial Indicator Set ............................... Crankshaft Seal/Sprocket installer ................. Crankshaft Sprocket Puller ....................... Dial Indicator .................................. Hydraulic Lifter Remover ...................... Hydraulic Lifter Remover ....................... Main Bearing Replacer .......................... Pin Remover & Installer ......................... Reamer Tool Set ............................. Ring Compressor ............................... Seal Installer ................................. Seal instalmer ................................. Spring Compressor ........................... Spring Tester .................................. Torsional Damper Puller ....................... Valve Guide Cleaner ............................ Valve Spring Compressor ........................

J-23590 J-6098 J-8520 J-8089 J-5239 J-22102 J-1619 J-8087 J-9290-01 J-3049-A J-8080 J-24086 J-5830-02 J-8037 J-35468 J-38841 J-5892-C J-8056 J-23523-E J-8101 J-8062

Order Directly from: Kent-Moore Tool Division 28635 Mound Road Warren, MI 48092 1-800-345-2233 Price and ordering information is available from Kent-Moore Tool Division.

Material Required Kerosene or Equivalent Cleaning Solvent Volvo Penta DuraPius" Synthetic Motor Oil Molykote Lubricant Plastigage (G ree n) Gasket Sealing Compound GMSilicone Rubber Sealer GMEngine Oil Supplement Volvo Penta Amphenol Crimping Tool P/N 322696 Liquid Neoprene For additional service information not covered in this manual, obtain the appropriate Chevrolet Engine WorkshopManual from: Helm Inc. P. O. Box 07130 Detroit, MI 48207

6-2

Engine/eng

intake Manifold Removal SeeOn-BoardService in the MFIDiagnostic (7.4 Gi, 7.4 GSi) - GMWorkshopManualfor upper intake plenum#7stallation.

coolant from both sides of cylinder block andexhaustmanifolds. [~] 2. Remove (:over (~) andflame arrestor. 3. Remove alternator. [~ 4. Removethermostat housing (~). [~ 5. Disconnectfuel line (~) at carburetor. Disconnectpurple/ white stripe wire (~ at chokecoil housing. 6. Disconnectthrottle cable at carburetor andanchorblock. 7. Remove main electrical harness from clamps on port side of manifomd and at front of manifold. Disconnectother ,wire connec= tions as necessary’. EEl 8. Removedistributor cap (E) and mark the position the rotor on the housing. Scribe a line on the distributor housing and intake manifold for reassemblyin the samepesition. Removethe distributor. 9. Unscrewattaching bolts, andremoveintake manifold and carburetor as an assembly. ~,CAUTIONif necessary to pry ma~, take care not to damage the sealing surfaces. 10. Remove and discard usedintake manifold gaskets and seals. Cleaning Remove all gasket material and clean the sealing surfaces of the manifold, cylinder block and thermostat housing. Remove excessive carbon deposits from exhaust passages,scale and deposits from cooling passages.Cleanthe manifoldin a suitable solvent and dry with compressed air. inspection inspect the manifoldfor cracks, damaged gasketsurfaces, or other defectsthat wouldmakeit unfit for service.

installation 1. Unstall new manifold seals on block, and new gaskets on cylinder heads. Use only side gaskets having metal inserts covering the center exhaust passage. Use sealer at water passages and where seals butt to gaskets. 2. Install intake manifold. Tighten bolts in the sequence shown. See Torque Specifications at end of section for torque figure. Check torque of the intake manifold screws annually. The center screws can become loose under normal usage. 3. install distributor with rotor and align exactly as markedduring removal. Install clamp and tighten screw to 25 ft. Ibs. (34 N.m). NOTE:if engine was cranked while distributor was out, complete ignition timing procedure must be followed. 4. install

distributor cap and high tension leads.

5. Place main wire harness under clamps on port side of manifold and at front of manifold. Makeother wire connections as necessary. 6. Attach throttle

DR3793

cable to carburetor and anchor block.

7. Connectpurple/white stripe wire to choke housing. Attach fuel line to carburetor. 8. Apply Gasket Sealing Compoundto both sides of a new thermostat housing gasket and pBaceit on manifold. Place lifting eye on long bolt, then install and tighten both botts to 12-16 ft. Ibs. (16-22 N-m}. 9. Install alternator and properly tension belt. Tighten mounting screws securely. Z~ 10. Install flame arrestor and tighten nut to 25-35 ft. Ibs. (2,8-4,0 N.m). Install flamearrestor coverandtighten nut 30-35 ft. Ibs. (3,4-4,0 N-m). 11. Attach battery cables at battery. Start engine and check for fuel and water leaks.

Z~ Safety Related

6-4

Englne/eng

!Exhaust Manifold Replacement Removal Drain water from respective exhaust manifold before beginning procedure. 1. Removehigh-rise exhaust elbow following High-Rise Exhaust Elbow Replacement.

procedure under

2. Carefully pull wires off spark plugs. :3. Loosen hose clamp at front of manifold, and pull off water hose. 4. Removemanifold attaching screws, nuts and washers. Discard nuts. Removemanifold and discard manifold gasket.

@

Cleaning ,Clean mating surfaces on manifold and cylinder head. Clean the "threads on the exhaust manifold bolts. inspection

DR2875

Inspect for cracks. To pressure check manifold, use a fabricated plate (~ as shownand a newelbow gasket (~) to seal water passage in manifold. Be sure to apply sealer to gasket, install rubber drain cap to manifold and secure with clamp. Attach a gear unit pressure tester © (such as Volvo Penta pressure gauge, P/N 9996398-5)to the water inlet hose. A bushing can be m, ade to secure pressure tester to hose. With the pressure tester attached to the manifold, submerge manifold in water. Pressurize the manifold to 10-15 PSI (22-25 kPa) and check for leaks. !Installation 18946

1. install

a newexhaust manifold gasket.

13~] ~ 2. Install manifold and secure with screws, washers and new Iocknuts. Tighten nuts to 20-26 ft. Ibs. (27-35 N-m). Tighten screwsto 24-28 ft. Ibs. (33-38 N-m). 3. Attach water hose to nipple at front of manifold and tighten clamp. .4. Attach spark plug wires to plugs. Makesure firing (correct.

order is 18944

5. install high-rise exhaust elbow following High-Rise Exhaust Elbow Replacement.

procedure under

,~ 6. Start engine and check for water and exhaust leaks.

En~=n~ ~ Safety

Related

6-5

HydraulicValve Lifter CheckingHydraulic Valve Lifter Whenchecking hydraulic valve lifters, rememberthat grit, sludge, varnish, or other foreign matter will seriously affect their operation. if any foreign substance is found in the lifters or engine where it maybe circulated by the lubrication system, a thorough cleaning job must be done to avoid a repetition of lifter trouble. To help prevent lifter trouble, the engineoil and oil filter mustbe changed as recommendedin General information Section. The engine oil must be heavy-duty type (for Service SG) and must also conform to General Motors Standard 6094-M to avoid detrimental formation of sludge and varnish. We recommend Volvo Penta DuraPlus" Synthetic Motor Oil. The boat owner should be specifically advised of these requirements when the unit is delivered. Faulty valve lifter operation usually appears under one of the fotlow[ng conditions: 1. RappingNoise Only WhenEngine is Started: Whenthe engine is stopped, any lifter on a camshaft Jobe is under pressure of the valve spring; therefore, leak downor escapeof oil from the nower chambercan occur. Whenthe engine is started, a few secondsmaybe required to fiml the lifter, particularly in colder weather, if noise occurs only occasionamly, it maybe considered normal, requiring no correction, if noise occurs frequentny, however, checkfor either oil too heavyfor prevaiJing temperatures, or excessivevarnish in lifters. 2. intermittent RappingNoise: An intermittent rapping noise that appears and disappears every few seconds indicates leakage at check bamaseat due to foreign particles, varnish, or defective surface of checkball or seat. 3. Noise at Idle and LowSpeed: If one or more valve lifters are noisy at idle speed and up to approximately 1200 RPM,but quiet at higher speeds, it indicates excessive leak downrate or faulty checkbale seat or plunger. With engine idling, lifters with excessive leak down rate may be spotted by pressing down on each rocker arm above the push rod with equal pressure. Recondition or replace noisy lifters.

6- 6

Englne/eng

4. GenerallyNoisyat All Speeds: Check for lowor highoil levelin crankcase. Highoil levelswill bechJrned by crankshaft andwill forceair bubbles into thelifters. Low oil levelsallowpump to pump air at highspeed.Withengineidling, strike eachrockerarmabovethe pushrodseveralsharpblows witha mallet;if noisedisappears, it indicates that foreignmaterialwaskeeping checkball fromseating.Stopengineandplace lifters oncamshaft base circle. If thereis lashclearance in anyvalveli~nkage, it indicatesa stucklifter plunger,wornlifter bodylowerend,or worncamshaft lobe. DR3785

5. LoudNoiseat Normal OperatingTemperature Only: J 9290-O1

If a lifter develops a loudnoisewhen the engine is at normaloperating tem,.~rature,butis quietwhen engine is belownormal temperature, it indicatesan excessively fast leakdown rateof scored lifter plunger.Recondition or replace lifter. Removal 1. Withair hoseandcloths,cleandirt fromcylinderheads andadjacent partsto ,avoidgettingdirt into engine. It is extremely important thatnodirt getsinto the valve lifters. 2. Remove intake manifold.Remove exhaustmanifolds. 3. Remove rockerarmcovers.Donotpry. If coversstick userubbermalletand strike coverendto jar loose.Loosen rockerarmnutsandpivot therockerarm freeof thepushrods. [~ ~] 4. Remove pushrods. Remove the hydraulic lifters thai require :serviceoneat a timeandplacethemin anorganizer rack.Thelifters mustbe installed in the sameborefromwhichthey wereremoved. NOTE: A stuck hydraulic lifter canberemoved usingTool J-3049-A(plier type)orToolJ-9290-01 (smide hammertype).

15.If less thana complete set of lifters is beingremoved, immediately disassemble oneor twofor presence of dirt or varnish.If lifters containdirt or varnish,it is advisable to remove all lifters for replacement. Otherwise, it will be .,satisfactory to service onlythoselifters thatarenotoperating properly. r~ 6. Examine the; camcontactsurfaceat lowerendof lifter body.If this surfaceis excessively worn,galledor otherwise damaged, discardthelifter assembly. In this case,alsoexamine the matingcamshaft lobefor excessive wearor damage. L~6. Engines with roller lifters. Examine the camcontactsurfacefor uneven wear.Examine lifters for stuckrollers, fiat spots,pits, missing or broken needle bearings. Check lefter to barrelclearence for excessive clearence or galling.

installation i

’ NoteBefore installinganynewlifters, coatthebottom of thelifter or lifter roller withMolykote or its equivalent. Engine/eng

6- 7

{ DR3786

1. Install valve lifters in cylinder block. If any newlifters or a new camshaft has been installed, an additive containing EPlubricant such as G.M. Engine Oil Supplement must be added to the crankcaseoil for break-in. 2. Install pushrods onto lifters.

Install intake manifold.

3. Pivot rocker arms in place and install rocker arm bolts. Tighten bolts to 40 ft. Ibs. (54 N-m). 4. Install rocker arm covers, using G.M. Sealer No. 1052289, and tighten nuts to 115 in. Ibs. (13 N.m). 5. Install exhaust manifold. Start engine and check for oil leaks at rocker arm covers.

Valve Spring andSeal Repair Removal 1. Removerocker arm cover. 2. Removespark plug, rocker arm, and push rod on the cylinder(s) to be serviced. EEl 3. Install Air Line Adapter tool J=23590to spark plug port and apply compressedair to hold the valves in place. ~-] 4. Using tool J-5892-C to compressthe valve spring, remove the valve locks, valve cap and valve spring and damper. 5. Removethe valve stem oil seal. Installation 1. Install

seal over valve stem and seat against head.

2. Set the valve spring and damper, valve shield and valve cap in place. Compressthe spring with toot J-5892-C and instalm oil seal in the lower groove of the stem, making sure the seal is flat and not twisted. NOTE:A light coat of oil on the seal will help prevent twisting.

DR3796

J 5892"C

-~

3. Install the valve locks and release the compressortool making sure the locks seat properly in the upper groove of the valve stem. NOTE: Grease may be used to hold the locks in place while releasing the compressor tool 4. Install spark plug and torque to 22 ft. lb. (30 N.m). 5. Install rocker armcover. Tighten nuts to 115 in. Ibs. (13,0 N-m).

DR37~

Cylinder Head Removal 1. Drain water from block and exhaust manifolds. Removeintake and exhaust manifolds. 2. Removevalve covers and spark pJugs. 3. Loosen rocker arm bolts and turn rocker arms aside. Remove pushrods. if lifters are to be serviced, removethemat this point. Otherwise protect the lifters and the camshaft from the entrance of dirt by covering the area with clean cloths. 4. Removecylinder head bolts, cylinder heads and gasket. Place cyJinder heads on bench, supporting them at each end on blocks of wood to prevent damageto gasket faces of heads. Disassembly 1. Removerocker arm bolts, ball seats and rocker arms. i[~ 2. Using tool J-8062, compressthe valve springs and remove the valve keys. Release the compressortool, and removerotators, springs and spring dampers, then removeoil seals.

DR3125

3. Removevalve from bottom of cylinder heads and place them and their respective valve springs in a rack in their proper sequenceso they can be assembledin their original positions. Cleaning 1. Clean aN carbon from combustion chambers and valve port using tool J-8089. I~ 2. Thoroughly cJean the valve guides using tool J-8101. DR3123

3. Clean all carbon and sludge from push rods and rocker’ arms. 4. Clean valve stems and heads on a buffing wheel. 5. Cneancarbon deposits from head gasket mating surfaces. 6. Washall parts in cleaning solvent and dry them thoroughly. inspection 1. Inspect the cylinder head for cracks in the exhaust ports, combustion chambers, or external cracks to the water chamber.

Engino/eng

6-9

DR3124

2. Inspect the valves for burned heads, cracked faces or damaged stems. [~ 3. Measure valve stem clearance as follows" a. Clampa dial indicator on one side of the cylinder head rocker arm cover gasket rail. b. Locate the indicator so that movementof the valve stem from side to side (crosswise to the head) will cause direct movementof the indicator stem. The indicator stem must contact the side of the valve stem just above the valve guide.

DR2101

c. Drop the valve head about 1As in. (1,57 mm)off the valve seat. d. Movethe stem of the valve from side to side using light pressure to obtain a clearance reading. If clearance exceedsspecifications, it will be necessaryto reamvalve guides for oversize valves. ~’~ 4. Checkvalve spring tension with tool J-8056 spring tester. [~ On all models, springs should be compressed and should check 74-86 pounds at 1.80 in. (4,57 crn} and 195-215 pounds at 1.40 in. (3,56 cm). Weaksprings affect power and economyand should be replaced. Repair DR3122

1. Valve Guide Bore: Valves with oversize stems are available for both inlet and exhaust valves. Refer to your parts catalog for available sizes. Use the reamer sizes from reamer tool set J-5830-02 to reamthe bores for new valves. 2. Valve Seats: Reconditioning the valve seats is very important, because the seating of the valve must be perfect for the engine to deliver the power and performance built into it. Another important factor is the cooling of the valve heads. Good contact betweeneach valve and its seat in the head is imperative to ensure that the heat in the valve head will be properly carried away.

6-10

E,~t.~

Several different types of equipmentare available for reseating valve seats; the =recommendations of the manufacturer of the equipment being used should be carefully followed to attain properresults. Regardlessof what type of equipmentis used, however, it is essential that valve guidesbe free from carbonor dirt to ensure propercentering of pilot in the guide. a. lnstall expanding pilot in the valve guide bore and expandpilot by tightening nut on top of pilot. b.

Placeroughingstone or forming stone over pilot andjust clean up the valve seat. Usea 46° stone for both the inlet and exhaustvalve seats.

c. Removeroughing stone or forming stone from pilot, install finishing stoneon pilot andcut just enough metal from the seat to provide a smoothfinish. d.

Narrowdownthe valve seats to the proper width for the intake andexhaust. SeeSpecifications at the endof this section.

U~°¢Ul°This operationis doneby grinding the port side with a 30 stone to lower seat anda 60° stone to raise seat. e. Remove ,expandingpilot and clean cylinder headcarefully to remove all chips and grindings from above operations. [~ [~ Valve seats should be concentric to within 0.002 in. total indicator reading.

Valvesthat are pitted canbe refacedto the properangle, ensuring correct relation betweenthe headand stem on a valve refacing machine.Valve stemswhich showexcessive wear, or valves that are warpedexcessively should be replaced. Whena valvo head which is warpedexcessively is refaced, a knife edgewill be groundon part or all of the valve headdueto the amountof metal that must be removedto completely reface. Knife edgeslead to breakage,burning or pre-ignition due to heat localizing on this knife edge.if the edgeof the valve headis less than l~z in. thick after grinding, replacethe valve.

Engine/eng

6-11

ao

If necessary, dress the valve refacing machine grinding °wheel to makesure it is smoothand true. Set chuck at 45 mark for grinding valves.

b. Clampthe valve stern in the chuck of the machine. c. Start the grinder and movethe valve head out in line with the grinder wheel by moving the lever to the left. de

Turn the feed screw until the valve head just contacts wheel. Move valve back and forth across the wheel and regulate the feed screw to provide light valve contact. Continue grinding until the valve face is true and smooth all around valve, ff this makesthe valve thin, the valve must be replaced as the valve will overheat and burn.

f.

Removevalve from chuck and place stem in "V" block. Feed vaJve squarely against grinding wheel to grind any pit from rocker arm end of stem. NOTE:Only the extreme end of the valve stem is hardened to resist wear. Do not grind end of stem excessively.

g. After cleaning valve face and cylinder head valve seat of grinding particles, makepencil marks about 1/4 in. apart across

the valve

face,

pJace the valve

in cylinder

head

and give the valve one-half turn in each direction while exerting firm pressure on face of valve. h. Remove valve and checkface carefully. If all pencil marks have not been removedat the point of contact with the valve seat, it will be necessary to repeat the refacing operation and against recheck for proper seating. i. Grind and check remaining valves in the samemanner. Assembly Whenreplacing valve springs, refer to the latest catalog for ordering information.

parts

EEl 1. Starting with number 1 cylinder, place the valves in the designated ports and assemble aim but the seal and locks. Then, using tool J-5892-C, compressthe spring (E) and install the seal (E) and locks ©. See that the seal is fiat and not twisted in the valve stem groove, and that the locks seat properly in the valve stem groove. D~795

6-12

Englno/e~

[~ Place valve spring in position toward the cylinder head.

with the closed coil

end

[2-~ 2. Checkthe installed height of the valve springs, using a narrow, thin scale cut away at the bottom (~). Measurefrom the top of the shim, or spring seat, in the headto the top of the. valve spring shield. Thecorrect installed height is 1 sl/¢4 ___1h2in. (45,64 mm_+0,787 ram) (~). installation 1. Wipeoff engine block gasket surface and be certain no foreign material has fallen into the cylinder bores, bolt holes, or the valve lifter area. it is goodpractice to clean out bolt holes with an air hose. This engine has special marine head gaskets. substitute automotive head gaskets.

Do not 47267

2. Install newhead gasket on cylinder block. Dowelsin the. block will hold the gasket in position. Alwayshandle gaskets carefully to avoid kinking or damageto the surface treatment of the gaskets. DO NOTuse any type of sealing material on head gaskets. The gaskets are coated with a special lacquer to provide a good seal, once the parts have warmedup. 3. Carefully set in place on the engine block dowel pins. 4. Clean and lubricate pound, install bolts.

the head boJts with Gasket Sealing Com-

~] 5. Tighten the head bolts with a torque wrench, in three progressive steps, following the sequenceshown. Step 1 - 35 ft. Ibs. (47 N.m) Step 2 - 65 ft. Ibs. (88 N.m) Step 3- 85 ft.

Ibs. (115 N-m)

[~ Damageto the cylinder block threads can result if bolts are not lubricated with Gasket Sealing Compound prior to installation or if the bolts are tightened excessively. Use an accurate ’torque wrench when installing head bolts and do not overtighten. Uneven tightening of the cylinder head bolts can distort the cylinder bores, causing compression loss and excessive oil consumption.

En~i~,,g

6-13

® ® ®

®

Z DR2g05

Timing Chain, Cover and Seal HarmonicBalancer Removal 1. Remove alternator andpowersteering belts, andcrankshaft pulley. 2. Attach tool J-23523-Eto balancer, and turn puller screwto removebalancer from crankshaft. DR357

Oil Seal Replacement NoteCoverneednot be removedto pry out and install

seal.

3. Pry oil seal out of front of coverusinga large screwdriver. [~ 4. Steel Covers:Coat seal lips with engine oil. Install new seal with lip towardinside of cover. Usetool J-35468to drive seal into position. E~] 4. AluminumCovers: Coat seal lips with engine oil. Install newseal with lip towardinside of cover. Usetool J-22102to drive seal into position.

DR3787 J 22102

Timing Chain Cover Removal 5. Remove circulating pumppulley, alternator brace, and power steering pump. 6. Drain cooling systemand removehoseat circulating pump.Disconnect temperature sender wire, then removecirculating pump and discard gaskets. 7. Remove oil pan. SeeOil Panin this section. 8. Remove the front cover-to-block attaching screws.Remove front cover and gasket. Timing Chain and Sprocket Replacement [~] 1. Crank engine until "0" markson camshaftand crankshaft sprockets are in alignment. In this position, engineis timedto fire No. 6 cylinder. 2. Removecamshaftsprocket bolts. Removesprocket and timing chain together. Sprocketis a slight press-fit for approximately1/8 inch. If sprocket doesnot comeoff easily, a light blow with a plastic-faced hammer on the lower edgeof the camshaftsprocket shoulddislodgeit. E~ 3. if crank sprocket requires replacement,use a two or three jaw puller suchas J-1619that pilots on endof crankshaftto pull off sprocket. 6-14

DR3579

I

L~ 4. Install crank sprocket using tool J-22102 to drive it into place over keyway. 5. Install timing chain on camshaft sprocket. Hold the sprocket vertical with the chain hanging below. Align the camand crank sprocket timing marks, and attach the chain to the crank sprocket. 6. Align dowel in camshaft with dowel hole in sprocket and install sprocket on camshaft. Do not hammersprocket onto camshaft. This may loosen rear camshaft welsh plug.

DR3577

7. Draw sprocket onto camshaft using the mounting bolts. Lubricare the timing chain with engine oil. Timing Chain Cover installation 1. Clean gasket surface on block and crankcase front cover’. 2. install section.

new oil pan gasket and oil pan. See Oil Pan in this

3. Coat the gasket with sealer and place in position on cover. Apply a lh inch bead of silicone rubber sealer, Genera/MotorsP/N 1052366(or equivalent) to the joint formed at the oil pain and cylinder block.

DR3576

4. Position crankcase front cover over crankshaft. Press cover downwardagainst oil pan until cover is aligned and installed over dowel pins on block. 5. Install the front cover-to-block attaching screws. 6. Tighten front cover to block bolts. See TorqueSpecifications at the end of this section for the torque figure. 24965

Harmonic Baiancer installation 1. Coat machinedouter surface of balancer hub with engine oil. Align keywayand start balancer onto crankshaft. [6~ 2. Using appropriate end of tool J-23523-E threaded into crankshaft, or a large washer and a 7/Is-20 x 4 in. bolt and nut ti~readed into center hole in crankshaft, tighten nut to seat harmonic balancer on crankshaft. ET~ 3. Removeinstalling tool. Install crankshaft pulley and t!ighten screws securely. Thread 7/16-20 × 2 in. bolt and thick washer into crankshaft and tighten. See Torque Specifications at the end of this section for the torque figure. 4.. Install circulating pumpand pulley, and tighten screws securely. Attach water hose to pump.

5. Install alternator and power steering pumpbrackets, install alternator and powersteering belts and adjust tension to specifications°

Camshaft Removal [~ 1. Removedistributor lating pump.

~). Removeintake manifold and circu-

2. Removerocker arm covers, loosen rocker arms, then remove push rods and valve lifters.

28257

3. Removecrankshaft pulley, harmonic balancer, timing chain cover, timing chain and camshaft sprocket. DE] 4. nnstaHtwo or three ~s-18 x 4 in. bolts in camshaftsprocket bolt holes and carefully pull out camshaft. Use care not to damagecamshaft bearings.

The camshaft has five bearings, all with the samejournal diameterof 1.9482 in. to 1.9492 in. These dimensions should be checked with a micrometer for an out-of-round condition, if the journals exceed 0.001 in. out-of-round, the camshaft should be replaced.

DR3796

The camshaft should also be checked for alignment. The best methodis by use of "V’" blocks and a dial indicator tool J-8520. The dial indicator will indicate the exact amountthat the camshaft is out of true. if it is out morethan 0.002 in. dial indicator reading, the camshaft should be replaced. When checking, the high reading of the dial indicator indicates the high point of the shaft. Examinethe camshaft bearings and if any bearing needs replacement, replace all bearings. Camshaft Bearing Re~ovai Camshaft bearings can be replaced while engine is disassembled for overhaul, or without complete disassembly of the engine. To replace bearings without complete disassembly, remove the camshaft and crankshaft leaving cylinder heads attached and pistons in place. Before removing crankshaft, tape threads of connecting rod bolts to prevent damageto crankshaft. Fasten connecting rods against sides of engine so theywilE not be in the way while replacing camshaft bearings.

6-1 6

Englne/eng

1. With camshaft removed,drive out expansion plug at rear of the rear camshaft bearing. Drive it out from the inside. ~ This procedure is based on removal of the bearing nearest center of the engine first. With this methoda minimumamountof turns is necessary to locate the remover in position to remove next bearing. 2. nnstall nut on puller screw and turn to end of threads on puller screw using tool J-6098. Index pilot over screw with open end toward nut on puller screw. 3. Insert remover with shoulder toward number3 bearing, making sure a sufficient amountof threads are engagedon the puller. 4l. Using two wrenches, hold screw shaft with one wrench while turning the front nut with the other wrench. After removing bearing from block, repeat operation for number2 bearingl. 5. Removetool and reassemble tool to remove number 4 bearing f~rom rear of engine. Assemble remover on driver handle and removefront and rear bearing. CamshaftBearing Installation The number one or front camshaft bearing should be installed first. This bearing will act as a guide for the tool and center the number two and three bearing being pulled in place. L~ 1. Assembleremover and installer tool on driver handl~e and instalU camshaft front bearing by driving towards center of cylinder block. 2. Using Tool Set J-6098, with nut then thrust washerinstalled to end of threads, index pilot in camshaft front bearing and install puller screw through pilot.

"\!

~’~ Align oil homesin bearing with oil holes in block before driving or pulling in place. ,.,.~’ Install nut on puller screwand turn to end threads on puller screw, index pilot screw, with open end of pilot toward nut. 4l. index number three camshaft bearing on screw, then turn installer on screw with shoulder toward bearing making sure a sufficient amountof threads are engagedon the puller. [4~ 5. Turn nut on screw puller to exert pressure on pilot until bearing is installed. 6. Removeinstaller four bearing.

Engine./eng

and repeat steps 4 and 5 for numbertwo and

6-17

f 47327

7. install rear bearing in samemanneras numberone bearing. Caution should be observedwhile installing rear bearing due to smaller size of oH pressure holes in rear camshaft bearing. improper alignment of rear camshaftbearing will result in restricted oil pressureto valve train. 8. Coat new camshaft rear plug O.D. with GMNo. 1052080 sealant,or equivalent,andinstall flush to 1/32in. (0,787ram)deep. Caminstallation 1. Lubricate camshaftjournals with engineoil. Whenever a newcamshaftis installed, lubricate the camshaft lobes with Molykoteor its equivalent. Also add onecan of G.M. EngineOil Supplementto crankcaseoil. 2. Install three %e-18x 4 in. bolts in camshaftbolt holes, install camshaft, being careful not to damagebearings. 3. install camsprocket (makingsure timing marksface outward), timing chain, rind timing chain cover. 4. install harmonicbalancerandcrankshaftpulley, install circulating pumpand connect coolant hose. 5. Install valve lifters, pushrods, rocker arms, andintake manifold. install rocker armcovers. 6. Install distributor andset initial timing.

Lubrication System Descriptionand Operation The oim pumpconsists of two gears and a pressure relief valve enclosedin a two-piecehousing, and is driven by the distributor driveshaft whichin turn is driven by a helix gearon the camshaft. Thepumpis flange mountedto the cylinder block with two bolts. Thepumpcover is equippedwith a pressureregulator valve that regulates oil pressure at approximately 40-60 PSi at 2000RPM. Thepumpintake is of the fixed screentype. A meshscreenfilters out small particles of dirt and sludge whichmaybe present. F~ A baffle incorporated in the intake screen has been designed to eliminate pressureloss dueto suddensurging stops, in the event that a screen becomesplugged, a steel grommetopens and bypassesoil to the pump.Oil passesthrough an openingin the mountingflange to the cylinder block, then into an oil filter adapter. Themainoil galleries run the full length of the crankcaseandcut into the valvelifter guideholesto supplyoil at full pressureto the lifters. The rocker armsand valves are lubricated by an oil channelin eachpushrod. Excessoil drains off andreturns to the oil pan through passagesin the cylinder headand block.

Connecting passagesdrilled in the crankcase permit delivery of oil at full pressure to all crankshaft and camshaft bearings, distributor drive gear and shaft, and the timing chain. Holes drilled in the crankshaft carry oil from the crankshaft bearings to the connecting rod bearings. Pistons and cylinder walls are lubricated by oil forced through a small notch iin the bearing parting surface on the connecting rod, which registers with the hole in the crankpin once every revolution. Piston pins are mubricated by splash.

RemoteEngine Oil Filter

28256

L-~ [~ A full flow oil filter (~) is mountedto a bracket attached to the port exhaust elbow. Twohoses connect it to an oil cooler and an engine block adaptor (~). L-~ [~ Oil exits the block through the rear opening © of the adaptor, and travels through a hoseto the rear oil coomerfitting, it leaves the front cooler fitting, and travels through a hose that connects to the filter bracket inner (starboard) opening (~. Return oil leaves the filter bracket at the outer (port) opening(~), travels through a hose and re-enters the engine at the forward opening (~) of the adaptor. If hosesare improperUyattached at adaptor or filter bracket, oil flow will be reversed. Oil pressure wiil drop and engine damagemay result.

19~A

©

3~ Normally, all engine oil passes from the block through an OEMfilter adapter ~). if the remote oil filter or lines become restricted, a spring loaded bypass valve ® opens in the adaptor and circulates oil back into the block. L~ Inspect bypass valve spring and vaJve disc (~ for proper operation or damage,if replacement of bypass valve is necessary, removebolts and adaptor. Clean valve chamberin block and replace adaptor.

Removal 1. Removetiming chain cover. See Timing Chain, Cover and Sea| in this section. 2. Removeoil dipstick

and withdraw oil using a suction pump.

3. Removeoil dipstick

tube. Removescrews, oil pan and g~sket.

4. Remove oil dipstick tube fitting

Engine/eng

from oil pan.

6-1 g

DR2906

Installation 1. Thoroughly clean all gasket sealing surfaces. ~] 2. Apply RTVsealer to the front and rear corners of the block. [~ 3. Attach gasket to block, install rear portion of oil pan seal in groove in rear main bearing cap. [~ 4. Install front portion of oil pan seal by pressing the corners into sealer applied to block. DR3788

5. install oil pan and tighten screws. See TorqueSpecificationsat the end of this section for the torque figure. [~ 6. install Orient fitting and flare nut. for the torque

dipstick tube fitting to pan; leave screw loose. and attach dipstick tube. Thentighten fitting screw See TorqueSpecificationsat the end of this section figure.

7. Fill crankcase with specified engine oil. the General Information Section.

See CrankcaseOil in

Oil Pump 31576

Removal and Disassembly 1. Removeoil

pan.

~] 2. Removepump to rear main bearing cap bolt, and remove pump, extension shaft and collar. NOTE:Baffle nuts have to be loosened. 3. Disconnect pump shaft from extension. Removefour cover attaching screws, cover, gasket, idler gear and drive gear and shaft.

\

,j

J

J~ DR3580

4. Removepressure regulator valve and valve parts. 5. if the pickup screen or pipe need replacing, replace the entire pump and pickup screen assembly. 6. Washall parts in cleaning solvent and dry using compressed air.

6-20

Englne/eng

Inspection Should any of the following conditions be found during inspection operations, the pumpand pickup screen assembly should be replaced. 1. Inspect pumpbody for cracks or excessive wear. inspect oil pump gears for excessive wear or damage. 2. Checkshaft for looseness in the housing. Checkinside of cover for wear that would permit oil to leak past the ends of gears. 3. Check the oil pickup screen for damageto screen or relief grommet. Check for oil in the air chamber. 4. Checkpressure regulator valve plunger for fit

in cover.

Assemblyand installation 1. Place drive gear’ and shaft in pumpbody. Install idler gear so that smoothside of gear will be toward the cover. 2. Install a new pump to cover gasket to ensure correct clearance of the gears.

end

3. install cover and attaching screws. Tighten screwsto 80 ill. (9 N-m), and check to see that shaft turns freely.

Ibs.

4. Install regulator valve plunger, spring, retainer and pin. 5. Assemble collar end of extension shaft assembly over pump driveshaft, aJigning tang of extension shaft with slot in end of pumpdriveshaft. 6. Assemblepumpand extension shaft to rear main bearing cap, aligning slot on top end of extension shaft with drive tang on lower end of distributor shaft. NOTE:Oil pumpshould slide easily into place, if not, remove and relocate slot or locate other problem. Install mounting screws and tighten. See Torque $;pecifications at the end of this section for the torque figure. 7. Tighten baffle nuts. 8, Install

oil pan using newgasket. Connectoil drain tube.

Measuring Camshaft Lobe Lift 1. Removerocker arm covers. Loosen rocker arms and pivot away from push rods.

[~ 2. Positionindicator with ball socketadapter(J-8520)on pushrod. Make surepushrod is in the lifter socket. t

3. Rotatethecrankshaft slowlyin thedirectionof rotationuntil thelifter is ontheheelof the camlobe.At this point, thepushrod will bein its lowest position. 4. Zerothe dial indicator,thenrotatethe crankshaft slowlyuntil the push rodreaches its highestreadingonthe dial indicator. ,~CAUTION :To preventelectrical sparks,accidentalenginestarting and fuel spraywhenever the engineis crankedthe following procedure must be folbwed. Gi andGSiModels:removegray andblack connectorsfrom igni= tioncoil. [~ GLE,’iodeis:Remove bothprimarywiresfromthe ignition coil terminals @andtape the ends. 7.4 GLModels withE.E.M.:Remove th 14-wireconnectorat the ignition module.Remove electric fuel pumprelay, 5. Compare the total lift recorded fromthe dial indicatorwith specifications. 6. If camshaft readings for all Iobesare withinspecifications,remove dial indicator assembly. 7. Install valvemechanism as outlined. Install rockerarmcovers.

RearMainBearingOil seal Replacement Removal Pryout rear crankcase oil seal. ,&,CAUTION: Becareful not to nick crankcaseseal surfacewhenremoving. Cleaningand Inspection [~ 2. Positionthe seal ontotool J-38841 ®so seal lip facesthe block. [~ 3. Positiontool J-38841againstthe crankshaft.Threadthe attaching screwsinto the tappedholesin the crankshaftandtighten securely.This will ensurethat the seal ®is installed squarelyoverthe crankshaft.Turn the handleuntil it bottoms thenremove the toot.

SafetyRelated

6-22

DR5655

Crankshaft Description o

Mainbearings are of the precision insert type and do no1 utilize shims for adjustment. If clearancesare found to be excessive, a newbearing, both upperand lower halves, will be required. Bearings are available in standardsize and0.001in., 0.002in., 0.010 in. and0.020in. undersize. Selective fitting of both rod andmainbearinginserts is necessary in production in order to obtain dosetolerances. For this reason you mayfind one-half of a standardinsert with one-half of a 0.001 irl. undersizeinsert whichwill decreasethe clearance0.0005in. from using a full standardbearing. Whena production crankshaft cannot be precision fitted by this method,it is then ground0.009 in. undersize on only those main journals that cannotbe properlyfitted. All journals will not necessarily be groundundersize.A0.009in. undersizebearingand 0.010 in. undersizebearingmaybe usedfor precision fitting in the same manneras previously described. Note If, for any reason, main bearing caps are replaced, shimmingmaybe necessary.Laminatedshimsfor each cap arc, = available for service. Shimrequirementwill be determinedby bearing clearance. inspection in general,(exceptNo. 1 bearing)the lowerhalf of the bearingshows a greater wearand the mostdistress from fatigue. If uponinspection the lower half is suitable for use, it can be assumed that the upperhalf is also satisfactory. If the lowerhalf showsevidenceof wear or damage,both upper and lower halves should be replaced. Neverreplace onehalf without replacingthe other half. These dimensions should be checked with a micromel:er for out-of-round, taper or undersize. If the journals exceed0.001in. out-of-round or taper, the crankshaft should be replacedor reconditioned to an undersizefigure that will enablethe installation of undersizeprecision type bearings. Thecrankshaft should also be checkedfor runout. To performthis operation, supportthe crankshaftat the front andrear mainbearing journals in "V" blocks, andindicate the runoutof both the rear intermediateandfront intermediatejournals, using a dial indicator. The runoutlimit of eachof thesejournals is 0.002in. If the runoutexceeds0.002 in., the crankshaft mustbe repaired or replaced.

E.~i,~.~

6-23

Main Bearing ~earance To obtain the most accurate results with Plastigage (or its equivalent), a wax-like plastic material which will compress evenly between the bearing and journal surfaces without damaging either surface, certain precautions should be observed. With the engine out of the boat and upside down, the crankshaft will rest on the upper bearings and the total clearance can be measured between the lower bearing and journal. To ensure the proper seating of the crankshaft, all bearing cap bolts should be at their specified torque. In addition, preparatory to checking fit of bearings, the surface of the crankshaft journal and bearing should be wiped clean of oil.

®

47397

1. With the oil pan and oil pumpremoved, and starting ,with the rear main bearing, remove bearing cap. NOTE: Wipe oil from journal and bearing cap before applying Plastigage. E~] 2. Place a piece of gauging plastic ~ the fuin width of the bearing (parallel to the crankshaft) on the journal. Do not rotate the crankshaft while the gauging plastic is between the bearing and journal. 3. InstalJ the bearing cap and evenly torque the retaining bolts to specifications. 4. Removebearing cap. The flattened gauging plastic found adhering to either the bearing shell or journal.

will

be

[~ 5. On the edge of gauging plastic envelope there is a graduated scale which is measured in thousandths of an inch. Without removing the gauging plastic, measure its compressed width (at the widest point) with the graduations on the gauging plastic envelope. Normally, main bearing journals wear evenly and are not out-of-round. However,if a bearing is being fitted to an out-ofround journal (0.001 in. maximum),be sure to fit to the maximum diameter of the journal, if the bearing is fitted to the minimum diameter and the journal is out-of-round 0.001 in., interference between the bearing and journal will result in rapid bearing failure, if the flattened gauging plastic tapers toward the middle or ends, there is a difference in clearance indicating taper, low spot or other irregularity of the bearing or journal. Be sure to measurethe journal with a micrometer if the flattened gauging plastic indicates morethan 0.001 in. difference. 6. If the bearing clearance is within specifications, the bearing insert is satisfactory, if the clearanceis not within specifications, replace the insert. Always replace both upper and lower insert as a unit.

47407

E~ If a new bearing cap is being installed and dearance is less ~han0.001 in., inspect for burrs or nicks; if none are founcl then install shims as required. ’7. A standard size,, 0.001 in. or 0.002 in. undersize bearing may produce the proper clearance. If not, it will be necessary to regrind the crankshaft journal for use with the next undersize bearing. 8. Proceed to the next bearing. After all bearings have been checked, rotate the crankshaft to see that there is no excessive drag. E3~ 9. Measure crankshaft end play (see Specifications) forcing the crankshaft to the extreme front position. Measureat the front end of the rear main bearing with a feeler gauge. 10. Install a newrear main bearing oil seal in the cylinder block and main bearing cap.

47417

Main Bearing Replacement E4~ 1. install a main bearing removing and installing tool J-8080 ~) in oil hole in crankshaft journal. NOTE:if such a tool is not available, a cotter pin maybe bent as required to do the job. 2. Rotate the crankshaft clockwise as viewed from the front of engine. This will roll upper bearing out of bJock. 3. Oil new selected size upper bearing and insert plain (unnotcbed) end between crankshaft and indented or notched side of block. Rotate the bearing into pRace,and removetool from oil’ hole in crankshaft journal 4. Oil new lower bearing and install in bearing cap. Install main bearing cap with arrows pointing toward front of engine. Torque main bearing cap bolts to specifications. (~nnecting Rod Bearing Replacement Connecting rod bearings are of the precision insert type and do not utiJize shims for adjustment. DO NOTFILE RODSOR ROD C~PS.If clearances are found to be excessive a new bearing will be required. Bearings are available in standard size and 0.001 in. undersize for use with standard size crankshafts. 1. With oil pan and oil pumpremoved, removethe connecting rod cap and bearing.

Engine/eng

6-25

DR2916

2. Wipethe bearings and crankpin dean of oil. Inspect the bearing for evidence of wear or damage. 3. Measurethe crankpin for out-of-round or taper with a micrometer. Rf not within specifications, replace or recondition the crankshaft. If within specifications and a newbearing is to be installed, measure the maximumdiameter of the crankpin to determine new bearing size required. 4. If within specifications, measurenew or used bearing clearances with Plastigage or its equivalent. if a bearing is being fitted to an out-of-round crankpin, be sure to fit to the maximum diameter of the crankpin, if the bearing is fitted to the minimumdiameter and the crankpin is out-ofround 0.001 in., interference between the bearing and crankpin will result in rapid bearing failure. a. Place a piece of gauging plastic the full width of the crankpin parallel to the crankshaft. (Note: Surfaces must be free from oil.) b. Install

the bearing in the connecting rod and cap.

c. install the bearing cap and evenly tighten nuts to specifications. Do not turn the crankshaft with the gauging plastic insta|led. d. Removethe bearing cap and using the scale on the gauging plastic envelope, measurethe gauging plastic width at the widest point. 5. If the clearance exceedsspecifications select a new, correct size bearing and remeasure the clearance. 6. Coat the bearing surface with oil, install the rod cap and tighten nuts to specifications. 7. Whenall connecting rod bearings have been installed tap each rod lightly (parallel to the crankpin) to makesure they have clearance. [~ 8. Measureall connecting rod side clearances (see Specifications at end of this section), between connecting rod caps.

Piston, Ring and Connecting Rod 4742.7

Piston and Rod Removal 1. Removeoil pan, oil pumpand cylinder head. Turn crankshaft until piston is at bottom of stroke. Place a cloth on top of piston to collect cuttings.

6-26

Engins/eng

2. Use a ridge reamer to removeany ridge and/or deposit.,~ from the upper end of the cylinder bore. After ridge and/or deposits are removed, turn crankshaft until piston is at top of stroke and removecloth and cuttings. 3. inspect connecting rods and connecting rod caps for cylinder identification. If necessary mark them. E2~ 4. Removeconnecting rod cap and instala tool J-5239 on studs. Push connecting rod and piston assembly out of top of cylinder block. It will be necessary to turn the crankshaft slightly to disconnect some of the connecting rod and piston assemblies and push them out of the cylinder. J 5239--~

Piston and Rod Disassembly 1. Removeconnecting rod bearings from connecting rods and caps. If connecting rod bearings are being reused, place them in a rack so they maybe reinstalled in their original rod and cap. 2. Removepiston rings by expanding them and sliding them off the pistons. Ring expandertools are available from local automotive stores.

DR3792

3~ 3. Using tools J-24086-20 (~) and J-24086-8 (~), place connecting rod and piston assembly in an arbor press with piston on support, then using remover, press piston pin out of connecting rod and piston. 4. Removeassembly from arbor press and remove tools, pin, connecting rod and piston.

piston

5. Clean varnish from piston skirts and pins with a cleaning solvent. DO NOTWIREBRUSHTHE PISTONSKIRT. Clean the ring grooves with a groove cleaner, and makesure oil ring holes and SlOtSare clean. 6 Inspect the piston for cracked ring lands, skirts or pin bosses; wavy, worn ring lands; scuffed or damagedskirts; or eroded areas at top of the piston. Replace pistons that are damagedor otherwise show signs of excessive wear. 7. Check fit of used piston pins. Use a dial bore gauge or telescoping gauge for the bore and a micrometer for the pin. Wear limit for piston to pin clearance is 0.001 in. maximum.Replace piston and pin assembly if wear is excessive.

Englne/en9

6-27

94136

Piston pins should be capable of supporting their own weight in either pin boss whencoated with light engine oil and at 60° F. Higher or lower temperatures will cause false indications.

--®

Piston pins are matched fit to the piston and are not available separately. Piston pins will not becomeloose enoughto cause a knock or tapping until after prolonged use, and in such cases a new piston and pin assembly should be installed. Piston and Rod Assembly 1. Lubricate piston pin holes in piston and connecting rod to facilitate installation of pin. [~ 2. Use J-24086-20, J-24086-9 and guide tools. Place connecting rod in piston and hold in place with piston pin guide (~) and piston pin ®. Place assembByon fixture and support assembly ©. 3. Using piston pin installer J-24086-9 (~, press the piston pin into the piston and connecting rod. 94137

Thepiston pin installer is a variable insertion length tool. The insertion length is varied by rotating the hub on the shaft muchlike adjusting a micrometer. An alphanumeric scale is used to determine the desired length for a given piston pin assembly. [~ After installer hub bottoms on support assembly, do not exceed 5000 PSi pressure, as this could cause structural damage to the tool. 4. Removepiston and connecting rod assembly from tool check piston for freedom of movementon piston pin.

and

Piston Rings Piston rings are furnished in various sizes. Refer to your parts catalog for sizes available. Oil control rings consist of two segments(rails)

and a spacer.

Compressionrings are the deep section twist type, 3/~2 in. wide. This type installed maintains diameter section.

compression ring takes its name, twist type, from its position which is cocked or twisted, it assumesand this position for life because the upper edge of its is chamfered, making the ring unbalanced in cross

6-28

Englne/eng

I~ All compression rings are marked with the letters "GM" ,cast in the upper side of the ring. Wheninstalling compression rings, makesure the side marked"GM" is toward the top of the piston. 1. SeJect rings comparablein size to the piston being used. it is important that each ring be fitted to its individual cylinder for proper gap spacing, and to its individual piston and groove for proper groove clearance. 2. Slip the compressionring in the cylinder bore; then, using the head of a piston, press the ring downinto the cylinder bore about 1/4 in. (6,5 ram). Using a piston in this way will place the ring square with the cylinder walls. 3. Checkthe space or gap betweenthe ends of the ring with a feeler gauge. If the gap between the ends of the ring is below specifications, removethe ring and try another for fit. Fit eachring separately to the cylinder in which it is going to be used. 4. New pistons, rings and cylinder bores wear considerably during seating and gaps widen quickly; however, engine operation will not becomeseriously affected if ring gaps do not become greater than 1/32 in.

860048

5. Carefulmyremoveall particles of carbon from the ring groove in the piston and inspect the groovescarefully for burrs or niclcs that might cause the rings to hang up. 4~ 6. Slip the outer surface of the top and second compression ring into their respective piston ring groove, and roll the ring entirely around the groove to makesure the ring is free and does not bind in the groove at any point, if binding occurs, the cause should be determined and removedby carefully dressing with a fine cut fileo However,if the binding is causedby a distorted ring, install a newring.

10755

0

Piston Ring installation E~ 1. Install the oil ring spacer in the oil ring groove, and insert antirotation tang in oil hole. Homdspacer ends butted, and install steel rail on top side of spacer. Position gap(~) at least one inch left of spacer gap (~ then install second rail on lower side of spacer. Position gap @at least one inch to right of spacer gap (~. 2. Flex the oil ring assemblyin its groove to makesure ring is free and doesnot bind in the groove at any point. If binding occurs, the cause should be determined and removed by carefully dressing with a fine cut fiae. However, if the binding is caused by a distorted ring, install a newring. 3. install second compression ring and mocategap (~, then top compression ring and locate gap O.

E~/..=

6-29

DR2908

[~ 4. Proper clearance of the piston ring in its piston ring groove is very important in maintaining engine performance and in preventing excessive oil consumption. Therefore, when fitting new rings, the clearance between the top and bottom surfaces of the ring grooves should be inspected. F~ 5. The upper compression ring should be fitted so that the clearancefalls within the Specifications at the end of this section. For clearance of lower compression ring, also see Specifications at the end of this section. 6. Assemblethe rings to the pistons as they are fitted, and makea final test of the ring fit in the grooves by repeating the fitting procedure given above. Piston and RodInstallation

860050

II ~~l

, 4

"

Ill

1. Lightly coat pistons, rings and cylinder walls with light engine oil. 2. With bearing caps removed, install bolts.

tool J-5239 on bearing cap

[~ Check position of ring end gaps. They must be aligned with each other as described previously. See Piston Ring Installation.

FRT. DR3783

3. install eachpiston in its respective bore, using tool 3-5239 on each assembly. The dimple ~) in the piston faces forward and the oil hole on the connecting rod should be to the center of the cylinder block. Guide the connecting rod into place on the crankshaft journals with the long detail of tool J-5239. [~ 4. Use tool 3-8037 (~) to compressthe piston rings. 5. Install bearing caps and check the bearing clearance as described previously.

47437

Cylinder Block inspection 1. Checkthe cylinder block for cracks in the cylinder wails, water jacket and main bearing webs. E~ 2. Checkthe cylinder walls for taper, out-of-round or excessive ridge at top of ring travel. This should be done with a dial indicator 3-8087. Set the gauge so that the thrust pin must be forced in about 1/4 in. (6,5 ram) to enter gaugein cylinder bore. Center gauge in cylinder, and turn dial to "0.’" Carefully work gauge up and down cylinder to determine the out-of-round condition, if cylinders were found to have more than 0.002 in. out-of-round, boring will be necessary. 860¢53

6-30

En~i~/,~

Cv|inder Conditioning "The performance of the following operations is contingent upon engine condition at time of repair. ff the cylinder block inspection indicated that the block was suitable for continued use except for out-of-round or tapered cylinders, they can be conditioned by honing or boring and honing. If the cylinders were found to have less than 0.005 in. (0,13 mm) taper or wear, they can be conditioned with a hone and fitted with the high limit standard size piston. A cylinder bore of less than 0.005 in. (0,13 mm)wear or taper maynot entirely clean up, when fitted to a high limit piston, if it is desired to entirely clean up the bore in these cases, it will be necessaryto rebore for an oversize piston. If morethan 0.005 in. (0,13 mm)taper or wearexists, they should be bored and honed to the smallest oversize th;~t will permit complete resurfacing of all cylinders= Cylinder Boring 11. Before using any type boring bar, the top of the cylinder block should be filed off to removeany dirt or burrs. This i,,~ very important. Otherwise, the boring bar maybe tilted which ,would result in the rebored cylinder wall not being at right angles to the crankshaft. 2. Place the hone into a cylinder bore, and expandthe stones until the honecan just be turned by hand. Connecta 1~ in. electriic drill to the hone, and drive hone at drill speed while moving hone up and downentire length of cylinder until hone begins to run free. During this operation, a liberal amount of kerosene should be used as a cutting fluid to keep the stones of the hone clean. Move hone slowly up and down with rough stones, but move hone up and downrapidly enoughwith the fine stones to produce ~3 final bore finish of very fine surface scratches in a crosshatch pattern of approximately 45° to 65° included angle. The marks should be clean but not sharp, and free from embeddedparticles or torn or folded metal. 3. Expandthe stones against the cylinder bore, and repe,at the honing operation until the desired bore diameter is obtained. 4. Occasionally during the honing operation, the cylinder bore should be thoroughly cleaned and the piston selected for the individual cylinder checkedfor correct fit.

5. Thoroughlyclean the cylinder bores with hot water and soap. Scrubwell with a stiff bristle brushandrinse thoroughlywith hot water, it is extremelyessential that a goodcleaning operationbe performed.If any of the abrasivematerial is allowedto remainin the cylinder bores, it will rapidly wearthe newrings andcylinder bores. In addition, the bearingswill be lubricated by the contaminated oil. Thebores should be swabbed several times with light engine oil and a clean cloth, and then wiped with a clean dry cloth. Cylinders should not be cleanedwith keroseneor gasoline. Clean the remainderof the cylinder block to removethe excess material spreadduring the honing operation. PistonSelection 1. CheckUSED piston to cylinder bore clearanceas follows: a. Measurethe "Cylinder Bore Diameter" with a telescope gauge2 1,~ in. (64 mm)from top of cylinder bore. the "Piston Diameter"(at skirt across centerline b. Measure of piston pin). c. Subtract piston diameterfrom cylinder bore diameterto determine "Piston to Bore Clearance." d. Calculate piston to bore clearance and determine if piston to bore clearanceis in the acceptablerange. 2. If usedpiston is not acceptable,checkif a newpiston can be selectedto fit cylinder bore within the acceptablerange. 3. if cylinder bore must be reconditioned, measurenewpiston diameter(across centerline of piston pin), then honecylinder bore to correct clearance(preferable range). 4. Markthe piston to identify the cylinder for whichit wasfitted. Handlethe pistons with care, and do not attempt to force themthrough the cylinder until the cylinder has beenbored to correct size as this type piston can be distorted throughcareless handling.

Circulating Pump [~ The Volvo Penta circulating pumpis manufactured specially for marineuse. it is serviced only as an assembly.Do not replace with an automotivecirculating pump. inspection 1. Remove alternator and powersteering belts. Graspcirculating pumppulley and checkendand side play. Turn pulley to checkfor drag. 2. Lookfor water leaking from indicator hole beneathpumpshaft behindpulley. Replacepumpif play, drag, or leakageare evident.

6-32

Removal andinstallation 11. Drain water from block and disconnect water hose from circulating pump. Removepulley. Removecirculating pump bolts, pumpand gaskets. 2. Use newpumpto block gaskets and sealer, install newpump assembJy on cylinder block andtighten bolts as specified, install pulley. Install alternator andpowersteering belts, then adjust tension. 3. Connecthoseto circulating pump.Lakeor tank test unit and checkfor leaks.

11981

Front Engine MountReplacement Removal [1--] 1. Remove two lag screws (~) and washersfrom mounts. 2. Lift enginewith 1500lb. (680 kg) minimum capacityhoist to allow removalof front mountand bracket. r2--~ 3. Remove three mountscrews and lock washers~).

11980

3~ ~ Prior to disassembly of front mount assembly, measure distance between large washer and flat on upper mount bracket. Disassembly 4~ 1. Removethree Iocknuts © and engine mount bracket ~) from mountbolt while holding bolt securewith socket (~). ~-J 2. Removetwo washers ® and engine mount bolt @from mount.

_T].

11979

Reassembly E6~1. Place small washer® on mountbolt and insert bolt up through mount, install large washerand secure with nut (~). Tightento 60-75ft. Ibs. (81-102N-m). ~ 2. Install upper inner nut and place engine mountbracket (~) on engine mount boJt. NOTE:Measuredistance between large washerand flat on upper mountbracket. Distance must be the sameas that prior to disassembly. 11978

E~,9~,~,’~ ~ Safety Related

6-33

11983

3. mnstail lock washer and top nut. Tighten nut to 50-70 ft. ibs. (68-95 N.m). installation 1. Spray the engine mount screws threads with Loctite primer or equivalent and allow to air dry. Apply Loctite or equivalent to the screws. Attach engine mount assembly to engine with three screws and washers. Tighten to 32-40 ft. Ibs. (43-54 N.m}. 2. Install lag screws and tighten securely. 2953

Height Adjustment ~] 1. To changeengine height, tighten or loosen nuts (~) and as required. 2. Lift engine with 1500 |b.(680 kg) minimum capacity hoist. Position engine at desired height. EEl 3. After setting mount position, turn upper inner nut (~) against underside of engine bracket and hold nut with a wrench. Tighten top nut (~) to 100-120ft. Ibs. (136-163 N-m).

High-Rise Exhaust Elbow Replacement

28262

Removal Drain water from respective exhaust manifold. 1. Loosen two clamps securing upper hose to elbow. 2. Port Elbow - Removetwo thru-bolts, lock washers, and washerssecuring remote oil filter bracket. Movefilter aside.

Z~ Safety Related

6-34

EngJne/eng

[3~ 3. Starboard Elbow- Remove two thru-bolts (~), lock washers, and washersattaching circuit breaker bracket. Set bracket assemblyaside. E~ 4. Lubricate inside of exhaust hose with a soapy water solution, then removeremaining elbow bolts. Tapelbow with a soft hammer to free it, then twist it out of the hose. Remove and discard the manifold gasket. installation 5L~ 1. Apply Gasket Sealing Compound to both sides of a new gasket ®, and place it on the manifold. Lubricate inside of exhausthosewith a soapywater solution to easeelbowinstallation.

3

19670

2. Twist elbowinto hoseandposition it on the gasket. Install the outer rear thru-bolt, washerandlock washer,andturn it in finger tight. [~ 3. Port Elbow- Position remoteoil filter at front of elbow. Install four thru-bolts, washersandlock washersfinger tig~ht. [3~ 4. Starboard Elbow- Position circuit breaker assemblyat front of elbow.Install two thru-bolts ~), washersandlock washers finger tight. Install remainingthru-bolts, washersandlock washers finger tight.

28265

5. Tightenall elbowthru-bolts to 12-18ft. Ibs. (16-24N-m). L~ 6. Properly position the two exhaust hoseclampsand tighten them securely.

26266

Eng|neleng

~ Safety Related

6-35

Exhaust Hose and intermediate Pipe Replacement Removal 1. Loosen eight clamps that attach the upper and lower exhaust hoses, and slide clamps down onto exhaust Y-pipe. [~ 2. Lubricate inside of lower hose with a soapy water solution, and push lower hose down onto exhaust Y-pipe. [~ 3. Twist intermediate pipe out of upper hose. Lubricate inside of upper hose with a soapy water solution if necessary to ease removal 4. Slide upper hose off high-rise exhaust Y-pipe.

elbow. Slide lower hose off

Installation 1. Lubricate inside diameter of 3.5 in. (8,89 cm) i.D. lower hose with a soapy water solution. Slide it all the way onto the exhaust Y-pipe. ~] 2. Onthe inside of the 4 in. (10,16 cm) IoD. upper hose, there is a circular rib 1.5 in. (3,81 cm) from one end. The ribbed end the hose must face the intermediate pipe (rearward) when it’s installed. Slide hose onto high-rise elbow until it seats. NOTE:if hose is not properly positioned, it will not completely engagethe high-rise elbow or allow secure attachment.

28264

3. With a twisting motion, insert intermediate pipe all the way into the upper hose. Slide the lower hose up until it’s halfway onto the intermediate pipe. Z~ 4. Slide four No. 68 clamps up onto the upper hose. Slide four No. 64 clamps up onto lower hose. Position clamps in their proper channels and tighten them securely.

Safety Related

6-36

16O41

Eng~ne/eng

EngineSpecifications

--

- -

7.4 and 8.2 GL, Gi, and GSi Type - No. of Cylinder ................................. Valve Arrangement ............................ Bore and Stroke: 7.4 models ................. 8.2 models .................

90° - V-8 Ow.=rheadValves

4.250 x 4.000 in. (107,95 x 101,6 mm) 4.468 x 4.000 in. (113,48 x 101,6 mm)

Piston Displacement 7.4 models ......................... 8.2 models .........................

454 Cubic Inches (7.4 Liters) 502 Cubic Inches (8.2 Liters)

Cylinder Numbers- Front to Rear Starboard ............................................. Port .................................................. Firing Order .................................... CompressionRatio 7.4 GL .................................................. 7.4 Gi, GSi .............................................. 8.2 GL .................................................. Water Temperature Control .......................... Thermostat Opens @.............................. Fuji Throttle Operating Range 7.4 GL, Gi .................................... 7.4 GSi ....................................... 8.2 GI .......................................

2-4-6-8 1-3-5-7 1-8-4-3-6-5-7-2 8.0:1 8.6:1 8.8:1 Thermostat 160°F (71°C) 4200 - 4600 RPM 4800 - 5200 RPM 4400 - 4800 RPM

Pistons: Production Clearance 7.4 Models ............... 0.003 - 0.004 in. (0,0762 - 0,1016 mm) 8.2 Models ................ 0.004 - 0.005 in. (0,1016 - 0,1270 mm} Service Limit .............................. 0.005 in. (0,127 mm) Piston Rings: Top Groove Clearance .... 0.0012 - 0.0029 in. (0,0304 - 0,0736 mm) Second Groove Clearance 0.0012-0.0029in. (0,0304-0,0736mm) Third Ring Groove Clearance 0.005- 0.0065 in. (0,127- 0,1651 mm) Service Limit ........................... +0.001 in. (+0,0254 mm) Top Ring Gap ................. 0.010 - 0.018 in. (0,254 - 0,457 mm) Second Ring Gap ............. 0.016 - 0.024 in. (0,406 - 0,609 ram) Third Ring Gap ............... 0.010 - 0.030 in. (0,254 - 0,762 mm) Service Limit ............................. +0.010in. (0,254 ram)

EngineSpecifications Piston Pins: Diameter ................ 0.9895 - 0.9897 in. (2,5133 - 2,5138 mm) Clearance ............... 0.0002 - 0.0007 in. (0,0050 - 0,0177 mm) Service Limit .............................. 0.001 in (0,0254 ram) RodFit, interference fit ... 0.0031 -0.0021 in. (0,0787-0,0533 mm) Connecting Rod: Bearing Clearance, New0.0011 - 0.0029 in. (0.0279 - 0.07386 mm) Bearing Clearance, Service Limit ............ 0.003 in. (0,0782 ram) Side Clearance ........... 0.0013 - 0.023 in. (0,0330 - 0,5842 ram) Crankshaft: Thrust .....................

0.006 - 0.010 in.( 0,1524 - 0,254 mm)

Main Journal Main Bearing Clearance, New No.l, 2, 3, 4 ............. 0.0017 - 0.0030 in. (0,0432 - 0,0762 mm) No. 5 ................... 0.0025 - 0.0040 in. (0,0835 - 0,0965 ram) Main Bearing Clearance No. 1,2, 3, 4 ............ No. 5 ...................

0.0010 - 0.0030 in. (0,0254 - 0,0762 mm) 0.0025 - 0.0040 in. (0,0635 - 0,1016 mm)

Crankpin Diameter 7.4 GL ................... 2.199 - 2.1996 in. (55,854 -55,8698 mm) 8.2 GL ..................................... 2.20 in. (55.88 mm) Taper and Out-of-Round, New............. 0.0005 in. (0,0127 mm) Taper and Out-of-Round, Service Limit ....... 0.001 in. (0,0254 mm) Camshaft: CamshaftBearing Journal E:tl.9482 - 1.9492 in. (49,484 - 49,509 mm) 7.4 Models Lift, intake .............. 0.2343 + 0.002 in. (5,9512 +_ 0,0508 mm) Lift, Exhaust............. 0.2530 + 0.002 in. (6,4262 + 0,0508 mm) 8.2 Models Lift, Intake and Exhaust.... 0.510+0.002in. 12,954_+0,0508mm)

8-38

E~ine/eng

EngineSpecifications Valve Systems: Lifter

Type ..........................................

Hydraulic

Rocker Arm Ratio 7.4 GL, Gi ............................................... 1.7:1 8.2 GL, 7.4 GSi .......................................... 1.7:1 Valve Adjustment ............................ zero lash + one turn °45 Valve Angle .............................................. °46 Seat Angle ............................................... Valve Seat Run-out .............. +0.002 in (0.0508 ram) Maximum Valve Stem Clearance Intake, New............. 0.0010 - 0.0027 in. (0.0254 - 0,0270 ram) Exhaust, New............ 0.0012 - 0.0,029 in. (0,0304 - 0,0736ram) Intake, Service Limit ...................... +0.001 in. (0,0254 mm) Exhaust, Service Limit .................... +0.002 in (0,0508 ram) Valve Seat Width, Intake ....... 1/32 to 1/16 in. (0,794 to 1,587 ram) Valve Seat Width, Exhaust ..... 1/16 to 3/32 in. (1,587 to 2,381 ram) Valve Spring Length ......................... 2.15 in. (54,41 ram) Valve Spring Installed Height, Installed ...... 1 51/64 in (45,641 mm) Valve Spring Pressure Ibs. @in. (kg @mm)compressed... [email protected]. (33,[email protected]) Ibs.@ in. (kg@ mm) compressed [email protected].([email protected]) Installed Height ............................. _+ 1/32 in. (0,794 mm) Valve Spring Fit In Damper......... 0.042 - 0.094 in. (1,06 - 2,38 mm) EngineLubrication: Type Oil Pump............................................ Gear Normal Oil Pressure, WarmEngine ..... 10 psi (70,3 kPa) @500 RPM 40-60 psi (281-422 kPa) @2000 RPM Crankcase Capacity 7.4, 8.2 GL ............. 7.4 Gi, GSi .............

6 qts (5,67 liters); 7 qts (6,62 liters) w/filter 8 qts (7,57 liters); 9 qts (8,51 liters) w/filter

C)il Grade Recommended 32° F (0 ° C) and above ................................. 0° F (-18 ° C) to 32° F (0° C) ........................ -0° F (-18 ° C) and below ..............................

SAE 30 SAE 20W-20 SAE 10W

TM Synthetic MotorOil, which is specially Werecommend Volvo PentaDuraPIus formulated for heavyduty marine use, and ideal for Volvo PentaEngines.tt providesbetter anti-wearqualities, especiallyduring long high speedoperation. In addition, it neutralizesacidscommon to all internal combustion engines,offers superiorcorrosionprotection, andis formulatedto offer better resistanceto oxidation andhigh temperaturesludge formation.

Fuel Recommendation............

See General Information Section

TorqueSpecifications Thefollowingspecificationsare for screwsizes not otherwiseshown in tables: ScrewSize No. 6 No. 10 No. 12 1/4 5/16 3/8

Ft. Lb.

2351018 -

3 4 7 12 20

In. Lb.

Nm

7 - 10 25- 35 35- 45 60- 80 120- 140 220- 240

0,8- t 3- 4 4- 5 7- 9 14- 16 24 - 27

Usea reliable torquewrenchto tighten the parts listed to preventstraining or distorting the parts or possiblydamaging the threads.Thesespecifications are for cleanthreadsonly. dirty threadsproducefriction whichpreventsaccuratemeasurementof torque. It is importantthat thesetorque specifications be strictly observed.Overtighteningto anyextent may damage threads or equipment,and mayrequire replacementof fasteners and damaged parts=

ITEM

Ft. Lb,

in. Lb.

Nm

60-84

27 27 34 40 34 20-24 43-54 7-9 43-54 22 7,9 9 35-41 41-49 16-22

20 20 25 30 25 15-18 32-40

CamshaftSprocket 7.4 GL,Gi 8.2 GL Circulating Pump Distributor Clamp DipstickTubeFitting Bellhousing BellhousingCover EngineMountto Block Oil Pan Oil Panto Front Cover Oil PumpCover PowerSteering PumpBracket Starter Motor ThermostatHousing Timing ChainCover 7.4 GL,Gi 8.2 GL Water Pump 7.4 GL,Gi 8.2 GL

32-40 200 70 80 28-30 30-36 12-16 106 120 30 35

6-40

12 13,6 40 47

Engine/eng

Torque

Specifications

(cont.)

iTEM

Ft, Lb.

ConnectingRod 7.4 GL,Gi 8.2 GL ExhaustManifold FlameArrestor FlameArrestor Cover Flare-Dipstick Tube FlywheelBellhousing Flywheeland Coupler FrontMount(top) Rocker Arm Cover

in. Lb.

48 73 20-26 25-35 30-35 15-18 3R-40 40-45 100-120 115

Cylinder Head Step1 Step 2 Step 3 ExhaustManifold Flywheelto Crankshaft Front Mount HarmonicBalancer 7.4 GL,Gi 8.2 GL ExhaustRiser Intake Manifold 7.4 GLGi (lower manifoldonly on Gi models) 8.2 GL MainBearingCap(All) 7.4 GL,Gi 8.2 GL Oil Pump 7.4 GL,Gi 8.2 GL Remote Oil Filter to Block Vibration Damper (use Loctite@242on bolt) Rocker Arm PowerSteering Pump Rocker ArmCover Oil Filter SparkPlugs

E.oi.~/..~

..... Nm

65 99 27-35 2,8-4,0 3,4-4,0 20-24 43-54 54-61 136-163 13

35 65 85 24.-28 70 65-75

47 88 115 33-38 95 81-102

85 90 12-18

115 112 16-24

30 35

40 47

100 110

135 149

65 70 20-25 ;!4 40

90 95 27-34 33 54

13-15

18-20 60-90 7-10 Oneturn after gasket.contact ;!2 30

6-41

NOTES

Section 7 Steering System

Table of Contents Mechanical (Non-power) Steering System - SX ............................ Cable Installation - SX................... Cable Removal - SX ..................... Lubrication - SX ........................ Sealants, Lubricants and Adhesives ....... Steering Tube Replacement- SX .......... Trim Tab Adjustment ....................

7-2 7-2 7-2 7-3 7-1 7-3 7-15

Power Steering System ..................... Belt Adjustment ........................ Cable Installation ....................... Cable Installation Problems.............. Checking Fluid Level .................... Cylinder Installation .................... Cylinder Removal ...................... Cylinder Servicing ...................... Description ............................. Diagnosis Chart ........................

7-4 7-10 7-13 7-20 7-9 7-12 7-11 7-12 7-4 7-16

PowerSteering System(cont.) External Leakage ...................... Feedback To Helm ...................... Hoses ................................ Hydraulic Fluid .......................... Lubrication ............................ PumpInstallation ........................ PumpLeakage ......................... PumpOperation ......................... PumpPressure Test .................... PumpRemoval .......................... Purging Air From Steering System......... Seala.nts, Lubricants, and Adhesives....... Special Tools ........................... Specifications - TorQ, ue ................. Steering Without PowerAssist ............ System Diagnosis ...................... System Operation .......................

Special Tools Required:

Materials Required:

Crowfoot Wrench(steering cable anchor nut) P/N 9995443-0 8.2 GL PumpPulley Remover P/N 9995444-8 8.2 GI_ PumpPulley Installer P/N 3854367-4 Volvo Penta Hydraulic Cylinder Rod Holder

Volvo Penta Grease Volvo Pentapowertrim/tilt & steering fluid or GMPower Steering Fluid Oexron, or Dexron II

Safety Warnings Beforeworkingon anypart of the engine,readthe sectioncalled Safetyat the endof this manual. Unlessinstructed otherwise, alwaysdisconnectthe battery cables from the battery beforeworkingon electrical systemto preventpossiblesparksor arcing in the enginecompartment. Beforestarting engineafter repair or maintenance procedures,alwsl.ys make sure enginecompartment is free of fuel vaporsto preventpossible fire and explosion. When workingon an enginethat is runningor being cranked,useextremecare to avoidgetting hands,fingers or clothingcaughtin the alternator, powersteering pump,supplypump,andcirculating pumpbelts, pulleys andother moving parts.

7-18 7-21 7-14 7-8 7-13 7-8 7-19 7-7 7-19 7-8 7-9 7-1 7-1 7-21 7-6 7-14 7-5

® C02740

18638

18640

Mechanical (Nonpower) Steering System SX Models Description [~ The mechanical steering system consists of a helm assembly ~), the steering cable ~), and attaching hardware © that connect the steering system to the inner transom shield and steering arm. Steering Cable Removal

6825

The steering cable is serviced as an assembly. J~ r-~ 1. To remove the steering cable, remove the cotter pin @and steering arm pin (~ securing the cable ram to the steering arm ®. Removeboth steering arm bushings (~. 2. Turn the heJmto the port full lock position. [~] 3. Loosen the cable anchor nut (j~,

and removethe cable.

Steering Cable installation

31837

Steering tube position in the anchor block is preset at the factory for proper centering of the steering system. Do not loosen the jam nut or changethe position of the steering tube. [~ ~ 1. Turn the steering wheel to fully extend the steering cable ram to its maximum extension. Lubricate the full length of the steering cable ram with Volvo Penta Grease. 2. Install

the steering cable ram through the steering tube.

3. While holding the steering cable in the steering tube, thread the steering cable anchor nut onto the steering tube until the steering cable anchor nut bottoms on the end of the steering tube.

2921

~ 4. Attach a crowfoot wrench O at a 90° angle to the torque wrench. Tighten the steering cable anchornut to a torque of 120 in. Ibs. {14 N-m).

Z~ Safety Related

7-2

3 EnQ~

~-~ ~] 5. Insert bushings (~) into steering arm. Install the steering arm pin ® through the top hole in the steering arm ® and through the hole of the steering cable ram. [2~ Z~ 6. Install the cotter pin @through the steering arm pin and secure by spreading the ends of the cotter pin. 7. Turn the steering wheel to fully extend and retract the steering cable ram (~. The steering arm should movefrom stop to stop as the steering ram moves from fully retracted to fully extended. Steering arm must not contact inside of transom cutout in either direction. Check for equal clearance of steering arm. Center the steering wheel and check centering of steering arm. Readjust as necessary.

3253

®

Manual Steering SystemLubrication [8~ Z~ Lubricate the steering ram with Volvo Penta Grease every 60 days.

Steering TubeReplacement- SX Models 1. Loosen the jam. nut and screw the steering tube out of the anchor block. Removethe jam nut from the steering tube.

DR172,

2. Screwthe jam nut (~) all the wayonto a newsteering tube. [-~ 3. Measure :3-1A in. (8,26 cm) (D in from the end of steering tube. Clean the following 1-1/4 in. (3,18 cm) of thread with Loctite primer or equivalent and allow to air dry. Apply Loctite or equivalent to the 1-1/4 in. (3,18 cm) thread area ~).

® m

[~ 4. Screw the anchor block onto the steering tube until the block is 3-%2 in. (8,02 cm) (~ from the end. This dimension positions the steering tube for accurate centering of the steering system. DR1727

5. Screw the jam nut up against the anchor block and tighten to a torque of 35-40 ft. Ibs. (47-54 N-m). Do not disturb the ~lnchor block position while tightening the nut. [~ ~ 6. If the anchor block was removed from the transom plate, apply a small amount of Volvo Penta Grease to both bushings, install the block with the original screws. Tighten both t:o a torque of 40-45 ft. ibs. (54-61 N-m). Securescrews with two cotter pins. [~ Filling the bushing pockets with grease can cause the screws to hydraulically lock and break transom plate when tighten.

80~2

80~1

® © ®

@ _____® @

Description

e The oim cooler (~) is a heat exchangerthat uses engine cooling water to keep the hydraulic fluid cool.

The power steering system consists of a mechanical cable from the helm to the inner transom plate, an engine mounted pump, and a power cylinder to movethe drive unit steering arm.

¯ A high pressure hydraulic hose @carries fluid from the pump to the control valve, and low pressure hoses (~) and (~ carry the fluid from valve to the oil cooler, and back to the reservoir.

I~ The hydraulic pump (~) is mounted on the front of the engine and is belt driven by the crankshaft pulley. The reservoir fill cap has a dipstick attached.

e The steering cable casing ~) attaches to the steering cylinder valve.

Power

Steering

System

¯ The cable ram passes thru the valve and attaches to the clevis ®. The drive steering arm (~) is also attached to the clevis.

e The control valve and cylinder ® is a single unit mountedto the inner transom shield.

7-4

Englne/eng

STARBOARD ,~

PORT

DR3506

SteeringTo Port - SteeringWheelTurningTo Left

System Operation NoSteeringInput - SteeringWheelNot Turning When there is no steering input from the helm, the spring @in the control valve keepsthe spool ® centered. Fluid from the pumpenters the control valvethru the pressureport L~), flows pastboth cylinder ports ~) and®with little restriction, then thru the return port @and back to the reservoir. There is a small equal force at both ends®and @ of the cylinder andthe cylinder doesnot move. With no steering input, the outdrive is held in one position and the boat movesin a constant turn or in a straight line.

E.~J~/..o

7-5

EEl When the helmis turned to port (either turning boat to left or straighteningfrom a right turn) the steering armis pulled to starboard. Thesteering cable casingpushesthe valve spool ®to port. Fluid from the pumpenters the valve at O, is routed to the rod-end outlet ®, and to the low volumeside of the cylinder @. The pumppressure movesthe piston andsteering armto starboard. Fluid in the high volumeside of the cylinder ® is forced out thru the valve from ~ to return port @andback to the reservoir. As long as the helmis turning to port this motioncontinues,swingingthe outdriveto port. When the helminput stops (steering wheelnot turning), the steering cable stopspulling the steering arm to starboard, and the steering casing stops pushingthe valve .,;pool to port. Whenthe spring @movesthe valve spool to a "centered" position, hydraulic fluid is again routed past both cylinder outlets. Thesteering cylinder has an equal force at both ends and stops moving. Thesteering system is thq._.n backto the NoSteeringinput condition describedpreviously.

STARBOARD

O

PORT

STARBOARD

DR3509

Steering To Starboard - Steering WheeJ Turning To Right

PORT

DR3507

Steering W’~hout PowerAssist E~ if the steering system is not providing power assist, the operator maystill steer the boat. Turning the steering wheel to port causes the steering cable fo pu[J the steering arm to starboard. This causes the cable casing to push the valve spool (~) to port against the stop about 0.125 in. (3,18 ram). The steering cable then transmits the full manualeffort to pull the steering arm.

~] Whenthe helm is turned to starboard (either turning boat to right or straightening from a left turn), the steering arm is pushed to port, The steering cable casing pulls the valve spoot (~ to starboard. Fluid from the pumpenters the valve at O and is routed to the piston-end outlet @)and to the high volume side of the cylinder (D. The pump pressure moves the piston and steering arm to port. Fluid at the low voiume side of the cylinder @is forced out and thru the valve from to return port ~) and back to the reservoir. As long as the helm is turning to starboard this motion continues, swinging the outdrive to starboard.

The fluid ® ahead of the piston is forced out of the cylinder thru outlet ~) into the valve, and thru return port @back to the reservoir. Additional fluid is drawnout of the reservoir thru the pressure inlet O and (~) to the opposite side of the piston ~).

Whenthe helm input stops (steering wheel not turning), the steering cable stops pushing the steering arm to port, and the steering casing stops pulling the valve spool to starboard. When the spring (~) movesthe valve spool to "c entered" position, hydraulic fluid is again routed past both cylinder outlets. The steering cylinder has an equal force at both ends and stops moving. The steering system is then back at the No Steering Input condition described previously.

7-6

More steering effort is required since all of the power required to steer the boat must be supplied by the operator, and additional force is required to move the fluid through the system when the pump is not operating.

Engine/eng

®®@ ®/

® ©

®

I-"

®

DR3007

DR3008

PumpOperation EEl During normal operation, fluid is drawn into dual pump intake ports ~) from the reservoir ®. Thereservoir is suppliedby a low pressurereturn line © from the powersteering oil cooler. The pumpoutput is thru ports (E). The vanes(E) are held against the pumpbore by pressure behind the vanes. The pump has sufficient output ® to allow quick boat maneuverseven at engineidle RPM.Thepumpoutput at high RPM is limited to about 2.3 gallons per minuteby a flow restriction orifice @. Thepumpoutput pressureis determinedby the resistance to flow of the system. Whenno steering changesare being made,the pressurewill be about 50-100PSI. Whenthere is steering input, the pressurewill be higher andwill dependon the steering forces required due to the boat attitude, drive trim position, throttle position and quickness of the maneuver. i[~ The pumpis protected from very high pressures by a pressurerelief valve ® that is located in the pumpbody. If the steering load becomes extremelyhigh, the relief valve willl open andlimit the output pressure(~) to about 1,000-1,100PSI. I~ Internal damageto the pumpwill occur if the system is operatedat relief valve pressurefor morethan a few seconds. ![~] Thepumphas a metric output fitting. metricfitting.

Useonly a hosewith a

2635

E,oi,~,g

7-7

Pump Removal [~ 1. Place an oil drain pan under pump.Disconnect high pressure hose @and return hose ® at pump.Do not lose O-ring on pressurehosefitting. Securehoseendsin a raised position to prevent fluid draining from hoses. Capor tape endsof hosesto keep out dirt. Drain pumpcompletelybefore removing. ~ [~3 2. Loosen pumpbracket mounting screws and removedrive belt. 20497

o 3.0 GSModels

[~

® 4.3 and 5.7 GL, Gi Models

E~

¯ 5.0, 5.8 FL and Fi Models

~]

¯ 7.4, 8.2 GL, Gi, Models

[~

3. Take out mountingscrews and removepumpfrom engine. [~] 4. Removepumppulley using apulley remover, then remove mountingbracket.

23916A

Pump Installation ~] 1. Attach mounting bracket to pump. Attach pulley using a pulleyinstaller. 2. Mountpumpbracket loosely on the engine. [~ 3. Makesure O-ring is in place and in goodcondition, then connecthigh pressurehosefitting @. Tighten fitting to 15-26ft. Ibs. (20-35 N.m). [~ 4. Connectreturn hose ® to reservoir. Tighten hose clamp to 12-17in. Ibs. (1,4-2,0 N.m). 5. Fill pumpreservoir with Volvo Pentapowertrim/tilt & steering fluid. Bleedpump,hoses,andvalve by turning pulley clockwise(as viewedfrom front of engine) until reservoir no longer showsair bubbles.Keepreservoir filled while purging air from system. 6. Install drive belt andadjust belt tension as describedunderBelt Adjustmentin this section. Do not pry against pumpreservoir while tighteningbelt.

24734A

7. Bleed entire systemas outlined under Purging Air FromSteering System. Hydraulic Fluid Usean approvedpowersteering fluid such as Volvo Penta power trim/tilt & steeringfluid or GMPowerSteeringFluid. If thesefluids 7-8

20510 Englne/eng

CheckingFluid Level I8~ 1. Run engine and rotate steering wheel lock-to-lock for a reasonably long period of time to warmup steering fluid, then shut engineoff. Remove reservoir filUer cap and checkif fluid level is at "HOT"mark on dipstick. [_9~_ 2. if fluid level is low, add recommended hydraulic fluid to bring fluid up to ’"HOT" mark on dipstick= Replacefiller cap. [~ Do not over-fill a cold reservoir. Fluid could overflow when system reaches operating temperature.

20847

Purging Air From Steering System When system components have been serviced, pump m~ast be refilled with fluid before engine is started. Perform the following steps to purge air from the steering system. will

Do not run pump even momentarily without be ruined or severely damaged.

fluid.

Pump

11. With engine "OFF," turn henmall the way to port. Add power steering fluid to bring fluid level to "COLD"mark on dipstick.

20846

2. Start engine, run momentarily and shut off engine. Recheck fluid level and fill to "COLD"mark. Repeatthis step as necessary until systemno longer requires additional fluid. 3. Complete purging of air from system by starting engine and turning wheel slowly lock-to-lock. Maintain fluid level above pumpbody in reservoir. 4. Returning fluid with air in it will often be in the form of foam and will have a light tan or red appearance.Maintain fluid level high enoughso foam is not drawn into pumpinlet. AHair must be eliminated from fluid before normaU steering action can be obtained, if excessive foam accumulates in reservoir it must be removed, or let unit stand for an hour and repeat steps above.

20509

5. After all air has beenpurged, return wheelto centered position. Continue to run engine for severaU minutes and then shut engine off. 6. With engine "OFF" and with fluid at normal operating temperature, recheck to makesure fluid level is at "HOT"markon dipstick. 7. Water test the boat to make sure the steering normally and is free from noise.

Engineleng

7-9

functions 31839

2391

DR4833

24278

Power Steering PumpBelt Adjustment ~’’"~[~ With engine stopped, the belt shoundbe tight enoughso that it will deflect 1/4" to 1/2" (6-13mm)whenpressed with the finger the point indicatedO. If the belt is too tight, excessivebelt wearcan occur.If it is too loose,slippagecanoccur,resulting in belt wearand poor powersteering operation. Belt tension shouldbe checkedafter 10 hoursof service andevery50 hoursthereafter. ®

® ®

PowerSteering PumpPulley Circulating PumpPulley 1/4" - 1/2" (6-13mm) Deflection

DR4935

Checkpowersteering pumpbelt tension ® midwaybetweenthe circulating pumppulley ® and the powersteering pumppulley O. Retighten newbelt, or checkold belt after 10 hoursof serviceandevery 50 hoursthereafter. ,~CAUTION: Whenadjusting a powersteering pumpbelt, neverpry againstthe pump reservoiror pull againstthe filler neck.

15930

3.0 GS Modeas [~ ~] Toincreasebelt tension:- Loosennut on lower pivot bolt, andloosen screwon brace behindpulley. Place W’ breakerbar into the squarehole in the pumpmountingbracket, and pivot pumpaway from engineas shown.While maintainingpressureon pump,retighten all mountingscrews.Recheckbelt tension. 4.3 GL, GS, Gi and 5.7 GL, Gi Modeas DR4934

E~ [~] To increasebelt tension: - Loosenpumpmountingbracket screws,insert a 1/2" breakerbar into the squareholein the pump mounting bracket, andpivot pumpawayfrom engineas shown.Whilemaintaining pressureon pump,retighten all mountingscrews. Recheck belt tension.

©

9--q 16067

DR2959

20572

All 5.0 and5.8 Models [~] To increase belt tension: - Loosennut on lower pivot bolt, and loosen screwon brace behind pulley. Place a 1/2" breaker bar into the square hole in the pumpmounting bracket, and pivot pumpaway from engine as shown.While maintaining pressure on pump,re[ighten all mounting screws. Recheckbelt tension.

7.4 GL, Gi, GSi and8.2 GL, Gi Models L-~ To increase belt tension: - Loosen mounting screws. Rotate bottom of pumpoutward by prying between the harmonic baJancer and the bottom tab of the powersteering pumpsupport bracket.

20606

Steering Cylinder E~ The steering cylinder assembly is a combination power cylinder and control valve. A piston rod clevis @provides the attachment to the steering arm and steering cable ram. The steering cable casing attaches to the threaded valve ®. Cylinder Removal

20504

1. Turn the helm full lock to port. Remove the cotter pin @and the steering cable pin @. 2. Hold steering tube with wrench. Loosensteering cable anchor nut ® and puff steering cable out of valve. 3. Remove cotter pin, then pull pin ® out of clevis and steering arm.

D3~] 4. Removeboth hose fittings @from valve. Raise hoses above pumplevel and cover the endsto keepout dirt. ,~WARNING: Do not movecylinder in or out until cylinder ha,,; been drained completely. A dangerousspray of fluid can discharge from cyfinder ports if the rod is moved in or out.

E.~i,~/.~

~ Safety Related

7-11

2058:

®

20580

2O579

[~ 5. Removecotter pins (~ and loosen both anchor screws until steering cylinder assembly can be removed. Cylinder Servicing [~ 1. Pry out steering pivot bushings © if they are to be replaced, if necessary they maybe carefuJly drilled in two places with a ~As in. (1,5 ram) drill bit and then removed. 2. Newbushings should be lubricated

and pushed into place. 20576

3. The cylinder rod should be wrapped with heavy paper or pasteboard and held in a vise with clamping blocks P/N 3854367-4. To remove the clevis (~), unscrew the 19 Iocknut (~). [~ Z~ 4. To reinstall clevis, tighten piston rod to clevis iocknut ® to a torque of 23-28 ft. Ibs, {31-38 N-m). Cylinder installation [~] 1. Install shield.

anchor screws (~ flush with inside of inner transom

!

[~ 2. Apply Volvo Penta Grease to both bushings. [~ Z~ 3. Position steering cylinder assembly on inner transom shield. Align bushings of steering cylinder with screws. Hand start both anchor screws to ensure alignment and engagement into bushings. Tighten anchor screws to a torque of 40-45 ft, Ibs. (54-61 N-m). [~ ~ 4. Install cotter pins ~ through holes in transom shield from transom side. Spread ends of cotter pins to secure. A~ Do not move cylinder rod if cylinder contains any fluid. dangerousspray of fluid maydischarge from the ports.

Z~ Safety Releted

7-12

A

20574

®

20504

31837

20570

[’7~ 5. Connecthosesto cylinder. Start eachfitting by hand.Tighten pressurefitting @to 10-12ft. Ibs. (-4-16N.m).Tightenreturn fitting to 15-17ft. Ibs. (2--23 N.m). E~z~ 6. Puli steering arm0 into hydraulic cylinder clevis ~). Align holes andinstall large pin ® from top of arm. Securelarge pin by installing andspreading endsof cotter pin. CableInstallation [~ Z~ 1. Turn the steering wheelto fully extendthe steering cable ramto its maximum extension.Lubricatethe full lengthof the steering cable ramwith VolvoPentaGrease.

205O6

.~ 2. Retract steering cable ram(~ andinsert ramthroughvalve @. [~ 3. Hold steering cable anchornut back on cable casing to make certain the steeringcableis completelyseatedin endof valve. [~2~] 4. Whileho{dingsteeringcabletight againstvalve, threadsteerir~g cableanchornut ® onto valve until snug.

20606

[~10~] [~ Z~ 5. Hole cable tube with a 22 mmwrenchon the flat @. Attach a crowfoot wrenchat 90° to a torque wrench® and ti~ghten the steeringcableanchornut to a torque of 120in. Ibs. (14 N-m). Z~ & Align cable ram(~ with steering cylinder clevis (~ and install small pin fromtop of clevis. Secure smallpin by inslLalling andspreadingendsof cotter pin. 7 Fill systemwith fluid and removeall air. SeePurgingAir From Steering System.

20605

Lubrication I_~ .L=L~Every60 days,greasethe steeringramwith VolvoPenta Grease. ,_.NoteDueto {ocal conditions, it maybe necessary to lubricate your engineat morefrequentintervals.

E,~ji~J.,~ Z~ SafetyRelated

7-13

20507

Hoses [~ Do not start nected.

engine with any power steering

hose discon-

The pumpoutput fitting has metric threads. Do not attach a hose with SAEthreads to the pumpfitting. After connecting power steering hoses, makesure that there’s ample clearance between the hoses and drive belts and other components. Hoses installed out of position may rub during operation and be damaged. if fluid return hose is removedat pump, be sure to use a "worm drive" clamp whenreinstalling it.

System Diagnosis Complaints of faulty steering are frequently the result of problems other than the steering cylinder assembly or pump. Conditions such as hard or loose steering, or vibrations, are often related to such factors as the drive belt; pump and cylinder mounting; fluid tevel; or incorrect installation of the steering cable. These factors should be checked and corrected before disassembJingor replacing parts of the steering system. System Checks Manyfactors affect power operation of the steering system. Some of the most commonproblem areas are: ¯ Fluid level. ¯ Looseor worn drive belt, or oily belt. ¯ Steering stern.

cable jammed against something in boat at

¯ Steering cable too short or steering cable too long. ¯ Loosely mounted components. e Loose pump pulley. After the problem has been found, determine the cause. For example,if the fluid level in the reservoir is found to be low, refill and bleed the system and check the entire hydraulic system for leaks. Just refilling the reservoir will makethe unit operate, but will not correct the condition that caused the problem.

Trim Tab Adjustment - SX Models Models With Power Steering Power steering models should not have trim tabs. if equipped, trim tab should be replaced with the trim tab hole plug Volvo Penta P/N 3850662-2. Models Without Power Steering The trim tab should be preset to dimension ~) 31/~ in. (83 mm), (5 ° ® for left-hand rotation) and dimension © 21/4 in. (57 rnm), (30° ¢~ for right-hand rotation). They should remain at this setting for all applications. If the trim tab is NOTset correctly, movetrim tab to the correct position. Tighten the trim tab screw to a torque of 28-32 ft. Ibs. (38-43 N.m). The boat maybe slightly easier to steer in one direction or the other due to steering forces or other reasons. To adjust, preset the trim to the dimensions above for models with power steering. Thencheck by running the boat in a straight line with a balanced load in an area where current and wind will not be a factor. To obtain equal steering effort, adjust the trim tab as follows: Safety Warning: improper trim tab adjustment can cause difficult steering. 1. Turn the steering wheel in both directions to determine the direction that requires the least amountof steering effort. 2. Loosenthe trim tab bolt and if less steering effort is required to port, movethe trim tab slightly to port. if less steering effort is required to starboard, movethe trim tab slightly to starboard. Twin engine installations require both trim tabs be moved an equal amountin the samedirection. 3. For twin engine installations wheretrim tabs are used, set both trim tabs to the sameposition. 4. Retighten trim tab bolt and recheck steering effort in both directions. Repeatprocedure until steering effort is equal in both directions. 5. After final adjustment, retighten the trim tab screw to 28-32 ft. Ibs. (38-43 N.m).

En~ow//~

Safety Related

7-15

DR4931

Power Steering SystemDiagnosis Chart Condition

Possible Cause

Correction

SYSTEMNOISE: Pumpnoise "chirp."

Loosebelt,

Adjust belt tension to specification.

Belt squeal.

Loosebelt.

Adjust belt tension to specification,

"Hissing" sound.

Somenoise exists in all powersteer- None; a slight "hiss" is normal and in ing systems. "Hiss"may be expected no wayaffects steering. whenturning the steering wheel, particularly at low speed.

Rattle

Pressurehose touching other parts of engine.

Adjust hoseposition.

Rattle or chuckle.

Steering systemlooseness.

Check cable nut and cylinder pivot points for wearor looseness. Replacebushingsif necessary.

Groan

Lowfluid level.

Find and repair leak. Fill reservoir and bleed system. Fill reservoir, find andrepair leak. Checkconnections, bleed system.

Air in fluid.

Locate restriction and correct. Replace part if necessary.

Growl

Excessive back pressure caused by hoserestriction,

Pumpgrowl.

Incorrect steering cable adjustment. Adjust cable per procedure. Eliminate Cableto boat interference, interference.

Whine in pump.

Pumpshaft bearing scored.

Flush system, replace pump.

SYSTEMOPERATION: Excessivewheel kickback or Steering cable attachment loose. loose steering (not boat wander). Air in system.

Replacepin. Tighten steering cable anchornut. Add fluid to pumpreservoir and bleed system.Checkall connections.

Steering wheel surges or Loose pumpbelt. jerks whenturning with engine running, especially Air in fluid. during slow speed operaInsufficient pumppressure. tion.

Adjust tension to specification.

Momentaryincrease in effort whenturning wheelfast to right or left.

Pumpbelt slipping.

Tightenor replacebelt. If oily, fix leak.

Lowfluid level.

Fill reservoir and bleed system.

High internal leakage.

Replacepumpif defective.

Fill reservoir, find andrepair leak. Bleed system. Replacepumpif defective.

Condition

Possible Cause

Hardsteering or lack of as- High internal leakage. (Powercylinder sist. or pump.)

Correction Replacepumpif defective. Replacecylinder if defective.

Cable jacket movementrestricted (bulkhead, fuel tank, jammedagainst inside of hull).

Do not clamp cable tight near output end. Eliminate interference.

Loosepumpbelt.

Adjust belt tension to specification.

Lowfluid level in reservoir.

Fill to properlevel, if excessivelylow, checkal~ lines andjoints for evidenceof external leakage, torque to specs.

Lackof lubricant in lube points.

Lubricate, relubricate at proper intervals.

Excessivefriction in steering linkage.

Find reasonfor excessivefriction; relubricate or repair.

Cablehas too tight a radius at output Eliminate small radius. end. Cable movementrestricted by tie straps, anchors,attachedwires, etc.

Remove all cable anchors, tie straps, etc. on cable between last bend and valve attachmentpoint.

Insufficient fluid pressure.

Replacepumpif defective.

Hardsteering to starboard. Cable too long or movement restricted Replacecable, or eliminate restriction. by bulkhead,etc. Hardsteering to port.

Cable too short or movement:re- Replace,cable, or eliminate restriction. stricted by bulkhead,etc.

Lowfluid pressure due to restriction in hoses.

Checkfor kinks in hoses.

Removekink.

Foreignobject stuck in hose.

Removerestricting hose.

Lowfluid pressure due to steering cylinder,

Pressureloss in cylinder due to worn Replacecylinder assembly. piston ring or scored housingbore.

Low fluid pressure due to steering pump.

Loosebelt.

Adjust tension to specification.

Lowfluid level.

Defective hoses.

Find and repair leak. Fill reservoir and bleed system. Fill reservoir, tighten fittings andhose clamps. Bleed system. Correct as necessary.

Pumpworn or damaged

Flush system, replace pump.

Air in fluid.

object or replace

Foamingmilky powersteer- Air in fluid and loss of fluid due to Checkfo~ leak and correct. Bleed sysing fluid, low level andpos- internal pumpleakage causing foam- tem. Keepfluid level up whenvery cold. sible low pressure. ing and overflow. If fluid level is correct andpumpstill foams, replace pump.

E~ng

7-1 7

External Leakage General Procedure 1. Wipe suspected area dry. 2. Checkfor over-filled

reservoir.

3. Checkfor fluid aeration and overflow. 4. Checkhose connections - tighten if necessary. 5. Determine exact point of leakage. 6. Whenservice is required, replace component. Leakage Checks Although someleaks are easily found, seepagetype leaks maybe difficult to pinpoint. Locate seepageleaks as follows: 1. With the engine off, wipe the complete power steering system dry (pump, hoses, and connections). 2. Check the fluid directed.

level in the pumpreservoir

and adjust as

3. Start the engine and turn the steering wheel from stop-tostop several times. 4. Find the exact area of leakage. Easily Fixed Leaks 1. Loose clamp on pump return

hose.

If fittings are not 2. Loose pump or cylinder hose fitting. cross-threaded, tighten to correct torque. See Torque Specifications. 3. DamagedO-ring on pumppressure fitting. 4. External meakageof power cylinder.

Replace O-ring.

Replace power cylinder.

5. Leakageof fluid in cooling water. Replaceoil cooler. 8. Damageor cracked hose. Replace hose. if the return hose is removed, the clamp must be replaced with a wormdrive clamp. Replace leaky hoses.

7-18

Engina/eng

,/

DR3009

Pump Leakage [~ 1. An over-filled pumpreservoir can cause a leak. The fluid in the steering systemexpandsas it heats up during normal usage and fluid level rises in reservoir. Excessfluid is forced through the breather cap hole where it may be sprayed over the engine by the drive belt. [1~ 2. Install newO-ring. Tighten hose fitting to 15-26 ft. Ibs. (20-32 N.m). If leakage persists, replace pumpor hose as required.

DR1443

2. Removefiller cap from pump reservoir and check: fluid level. Flit/pump reservoir to full mark on dipstick. Start engine, momentarily hold steering wheel against stop, and check connections at Tool J-5176 for leakage. 3. Bleed system as outlined From Steering System.

under Purging Air

4. Insert thermometer Kent-Moore Tool J-5421 into reservoir filler opening. Start the engine and movesteering wheel from stop-to-stop several times until thermometerindicates that hydraulic fluid has reached its; normal operating temperature of approximately150° to 190° F (65° to 88° C).

[~ 3. Check torque on fitting (~). Tighten to torque of 37-75 ft. Ibs. (50-102N-m). If fitting not loose, replace pump. [1-7 4. Checkfluid level ©. If leakage persists with fluid at correct level and cap tight, replace cap or pump. E~ 5. Somenon-repairable pump leakage areas are markedwith the oil-drop symbol. If leakage occurs in these areas, replace pump.

PumpPressure Test r2~ 1. With engine off, disconnect high pressure (output) hose at pump. Use a spare pressure hose (~ to install Kent-Moore Tool J-5176 (~) between pump and steering cylinder pressure hose (~). Gauge must be positioned between shutoff valve and pump. Connect steering cylinder pressure hose to shutoff valve. Openshut-off valve.

7-19

5. Checkfluid level; add fluid if required. When engine is at normal operating temperature, the pressure reading on the gauge (valve open) should be in the 50-100 PSI (345-690 kPa) range. if pre,ssure exceed,s specifications, check the hosesfor restrictions. Z~ 6. Pumprelief valve pressure can be checked by momentarily closing the shutoff valve. Do riot leave valve closed longer than it takes to read gauge; high hydraulic pressures are developed. Relief valve pressure is approximately 1000-1100 PSI (6895-7584 kPa). Replace pumpif fluid pressures or temperature do not meet specifications.

Cable Installation

Problems

Thehydraulic valve reacts to steering cable casingmovement. Total valve movement is about1/4 inch. This small motionis sufficient to operatethe valve anddirect hydraulicpressureto the appropriateside of the steering cylinder. Anyrestriction of movement of the steering cablecasingat the sternof the boatwill limit or restrict the movement of the valveandwill result in hardsteeringin oneor bothdirections. When replacingthe steering cable, the following points mustbe followedfor properpowersteering systemoperation:

ir

DR1450

[~ 1. Donot install a cablethat is too short. Inadequate length will put tension on the cable casing, andcausebinding of the steering cable. This will restrict valve movement, causehard steering to port anda tendencyto self steer to starboard. 2. Donot install a cablethat is too long. Excessive length will pushon the cable casing, andcausebinding of the steering cable. This will restrict valve movement, causehard steering to starboard anda tendency to self steer to port. DR1451

3. Donot position steering cablein a sharpbendof less than 6 in. radius. Tight bendswill causebindingandlimit control valve movement.This will contributeto hardor uneven steering, or roughsteering wheel movement. [~ 4. Donot jam anything against cable at the engineend. Do not bind cableagainstinside of boat or againstfuel tanks, battery boxes or flotation blocks. Jamming the steering cablewill restrict steering cable movement and causehard steering. E~ 5. Do not interfere with or restrict steering cable movement throughthe last 90° of bendto the engine.Cableretainers,clips, clamps or tie strapsshouldnot be usedin a manner that will restrict the cable movement near the engine. Do not attach wiring harnessor control cablesto this endof the steeringcable. Z~Donot restrict steering cable casingmovement. Any restriction of the cablealso restricts the vatvemovement. Thiswill limit or stop hydraulic assist, or mayhold the vanvein onesteeringmode.

SafetyRelated

7-20

DR1452

FeedbackTo ’The Helm The steering system requires at least a little friction in the helm (and cable) to prevent hydrodynamic forces on the gearcase from feeding back and turning the steering wheel without the operator activating the power assist system. This mayhappenon single engine instaiJations (or on twin engines having both drives rotating in the samedirection).

If the steering wheel turns to both starboard and port, then helm friction must be increased slightly. This will atlow the powersteering system to hold the desired steering position. If the helm always turns in one direction (whenit turns), it maybe causedby a steering cable that is too short, too long, or has restricted movemen1:. See Cable Installation Problems. Twin engine problems may be corrected by having the drive,s rotate in opposite directions.

Runthe boat in a straight line in opposite directions at normal cruising speed with the drive trimmed in both a "bow up" position and in a "bow down" position. In each trim position, momentarily release the steering wheel to see if the wheel is turned by the gearcase, and in which ,direction.

Specifications PowerSteering PumpRelief Valve Pressure (except 8.2 GL) .......

1000-1100psi (6895-7584 kPa).

Torque Specifications Component

Torque

Anchor Screw - Cylinder assy. to TransomPlate

40-45 ft. ibs. (54-61 N-m)

Bolts - Power Steering PumpMounting Bracket

25 ft. Ibs. (34 N-m)

Bolts - Power Steering PumpMounting

25 ft. Ibs. (34 N-m)

Fitting

- Power’ Steering Pump

37-75 ft. Ibs,. (50-102N-m)

Fitting

- Power Steering PumpHose

15-26 ft. Ibs. (20-35 N-m)

Fitting - Inlet Control Valve Hose

10-12 ft. Ibs. (14-16 N-m)

Fitting - Outlet Control Valve Hose

15-17 ft. Ibs. (20-23 N-m)

Hose Clamps - Oil Cooler and Power Steering Pump

12-17 in. Ibs. (1,4-2,0 N-m)

Jam Nut - Anchor Block

35-40 ft. Ibs. (47-54 N-m)

Locknut - Piston Rod To Clevis

23-28 ft. Ibs. (31-38 N-m)

Nut - Steering Cable Anchor

120 in. Ibs. (14 N.m)

Screw- Trim ~zb

28-32 ft. Ibs. (38-43 N-m)

E,,~,i,~,g

7-21

NOTES

7-22

Section 8 Throttle andShift Controll Systems

Table of Contents

Volvo Penta Models installation of SAECables ,~hlft Cable to Drive ................................... Throttle Cable to Engine ............................... Replacementof RemoteControl Cables .................

8-3 8-5 8-6

Z~ Safety Warnings Before working on any part of the engineor related systems, read the section called Safety at the end of this manual. Unless instructed otherwise, always disconnect the battery cables from the battery before working on electrical systemto prevent possible sparks or arcing in the engine compartment. Before starting engine after repair or maintenance procedure.,;, alwaysmake sure enginecompartment is free of fuel vapor.,; to prevent possible fire and explosion. Whenworking on an engine that is running or being cranked, use extreme care to avoid getting hands, fingers or clothing caught in the alternator, power steering pump, supply pump, and circulating pumpbelts, pulleys and other movingparts.

Engine/eng

8-1

Materials Required Volvo Penta Grease Molybdenum Grease

Safety Warnings Before working on any remote control system, read the section called Safety at the end of this manual. Replace any locking type fastener (example: iocknut or patch screw) whoselocking feature becomesweak. Definite resistance to turning must be felt or locking fastener is not suitable for continued use. Replace only with authorized replacementpart or equivalent,

The following text will cover the replacement of parts, repair and testing of Volvo Penta remote controls used with Volvo Penta SX stern drive applications. No single test of the remote control after reassembly will, by itself, always ensure a properly functioning unit. To ensure correct assembly and operation, you must follow aii the assembly instructions in this section.

8-2

Engine/eng

®

\

®

~045

34044

34041

installation of SAECablesto Engine/Drive Shift Cableto Drive Unit installation ~:

_--

Notel Remote control shift andthrottle cablesmustbe SAEtype cables --Note-1. If the throttle cableis attachedto the throttle armand anchorblock, remove it fromboth. Thethrottle cablemustbe disc, onnected fromthe throttle armprior to shift cableinstallationand adjustment to prevent"loading"the controlboxandadverselyaffectingshift adjustments.

34039

2. Notethe positionof small seal ~ andlarge seal ® onthe shift cable. Remove andretain jamnut, smallseal, andlarge seal fromthe shift cable. [~ 3. Applya light coatingof VolvoPentaGreaseto the endof the remotecontrolshift cablecasing.Slide shift cablethroughshift cabletubeuntil it ,appearsonthe outsideof the transom. 34037

[~ 4. Foreaseof installationof shift cable,turn driveunit to port, Reinstall the retained large seal (~ and small seal (~ onto the shift

cablein the samepositionas notedin step2, [~ 5. Loosencable clampscrew@and pull clampout. [-~ 6. Slide shift cablethrough pivot housing andfrive unit. r_~ 7. Slide clampin fully, engaging the shift cableanchorgroove. ~CAUTION: Tighten clampscrew securely.

~-~

~,

Safety

Related

34038

8-3

34427

34421

34425

[~ 8. Rotateshift lever to extendbelmcrank(~). Remove cotter pin, flat washer,andanchorpin (~). 9. Threadanchorpin halfwayonto remotecontrol cable end. [~ 10. Rotate shift Ueverback to neutral detent position, then move remotecontrol handleto its neutral detent position. Turnanchorpin iN or OUT until it aligns with centerof bellcrankslot (~). [~ 1 1. Install flat washerandcotter pin.

34424

~CAUTION : Secureby’ spread/ncj end of cotter pin. Install jam nut (~ andtighten securelyagainst cotter pin. [~ 12. For left handrota~onpropellers, the bellcrank link mustbe installed into the starboardhole(~) of the shift lever. [~ 13. For right handpropellers, the bellcrank link mustbe installed into the port hole(~ of the shift lever. 34426

34420

SafetyRelated

8-4

34423

34030

34423A

34419

E~[~ 14. To reposition bell crank link, removecotter pins @and pin ® from clevis, then rotate linkage @out of bell crank. [~ E~15. Install linkage @into opposite side of bell crank. Install washerandcotter pin @.Position clevis on starboardside of shift lever andinstall pin ® andcotter pin @. [~ 16. Reinstall rear cover and securewith three original screws

@. Throttle Cableto EngineInstallation

34031

Note Moveremote control handle to NEUTRAL detent position. Turn propeller shaft and shift into the FORWARD gear detent position, then pull HALFWAY BACKtowards NEUTRAL.This positions the control for proper throttle cable adjustment.Failure to follow this procedurecan bind the shift linkage in the control, and produce"hard shifting." E~1. Align internal boss ® of trunnion with throttle cable groove ®. Presstrunnion on throttle cable until seated. iN£te I~ Carbureted Models Only: Engine anchor bracket may havetwo sets of anchorblock holes. Thetop set (marked)is for the 4Vcarburetor models,and the bottomset is for the 2Vcarbureted models.

34112

®

E~ 2. Install openend @of trunnion in anchor block. Install screwin anchorMockand position throttle cable assemblyin selected set of holes. ,~CAUTION : Nut ® must be against the anchor bracket, tighten securely.

® 34751

DR4977 Engme/eng

®

0R4978

DR4979

DR4980

DE]3. Install throttle armconnectoronto the throttle cable. Pult connectorfroward O to removeall end play from throttle cable, then turn the connectorin until holesalign with the throttle arm@. ¯ "kCAUTION ¯ Throttle arm connector O must have a minimumof 9 full turns of 1~ in. of throttle cablethreadengagement. N°tel If throttle armconnectorhole cannot be adjusted to align with the throttle arm,checkfor propercable installation in the remotecontrol box. 34428

[~] CarburetedModels-Install connector onto throttle arm. ,~,.CAUTION : Install washerandcotter pin ®, andsecureby spreading end of cotter pin. Tighten jam nut @against connector. Replacementof RemoteControl Cables Should it becomenecessaryto removeor replace the remotecontrol cables, the attachmentat the engineis very important. Follow these steps for removaland installation of remotecontrol cables. Before beginning, shift remote control handle into NEUTRAL detent position; propeller shouldrotate freely.

34424

Throttle Cable RemovalFromEngine [~ 1. Removecotter pin and flat washer® or lock nut (~ from throttle arm. IT~ 2. Loosenanchor retainer nut ~ and rotate retainer @away from cable trunnion. Remove throttle cable from throttle armand anchorbracket. Shift CableRernovalFromDrive

34O38

[T~ 1. Removesterndrive rear cover. Removeflat washer and cotter pin from anchor pin. Remove jam nut ® from shift cable core wire. [~ 2. Remove anchor pin @from bell crank slot. Unscrewanchor pin fromshift cablecore wire. 3. Loosenscrewand slide retainer out of shift cable anchor groove. Remove the shift cable from drive and transomshield. 8-6

Section9 Cooling System

Table of Contents Components Circulating Pump- Engine .................................... Hoses, Clampsand Drain Plugs ............................... Manifold and Elbows ........................................ Thermostat ............................................... SherwoodRaw Water Pump.................................. Johnson RawWater Pump................................... Description ................................................. Draining Engine Block or Exhaust Manifold .............................. Pivot Housing ............................................. PowerSteering Oil Coolers ................................... Sherwood RawWater Pump.................................. Johnson RawWater Pump................................... Thermostat Replacement..................................... Troubleshooting isolating Problem ............................................ Possibilities to Consider ...................................... Problem Checkpoints ........................................ Quiz the Customer........................................... Water flow Diagrams Drive Unit and TransomShield ................................. 3.0 GS .................................................... 4.3 GL, GS, 5.7GL ......................................... 5.0, 5.8 FL ................................................ 4.3, 5.7 Gi ................................................ 5.0, 5,8 Fi ................................................. 7.4,8.2 GL ............................................... 7.4, 8.2 Gi, GSi ............................................

9-17 9-16 9-17 9-16 9-18 9-21 9-2 9-23 9-24 9-24 9-18 9-21 9-25 9-4 9-4 9-6 9-3 9-8 9-9 9-10 9-11 9-12 9-13 9-14 9-15

Safety Warnings Before working on any part of the engine, read the section called Safety at the end of this manual. Unless instructed otherwise, always disconnect the battery cables from the battery before working on electrical system to prevent possible sparks or arcing in the engine compartment. Before starting engine after repair or maintenance procedures, always make sure engine compartmentis free of fuel vapors to prevent possible fire and explosion. Whenworking on an engine that is running or being cranked, use extreme care to avoid getting hands, fingers or clothing caught in the alternator, power steering pump, supply pump, and circulating pump belts, pulleys and other moving parts.

Description Water is supplied to the engine by meansof an impeller type pump (raw-water pump). The raw’water supply pump is mounted on the engine. Water suppled to the engine is circulated in the engine by means of a centrifugal type pump (circulating pump). The raw-water pumpused on this model is a self priming impeller type. The pump is mounted on the engine and belt driven. During low speed operation the impeller functions as a positive displacement pump. At higher speeds it functions as a combination centrifugam and positive displacement pump. The shape of the housing and liner cause an eccentric action of the impeller blades during engine operation. During periods of high speed operation, the resistance of the water on its way through the pumpis sufficient to prevent the ends of the impeller blades from making contact and following the inside perimeter of the pumphousing. The blades merely flex in toward the center of the impeller to perform as a combination centrifugal and positive displacement pump. All Models: The circulating pumpis mountedon the front of the cylinder block, it has a pulley bolted to the pumpshaft hub at its forward end. This in turn is driven by meansof a belt from the crankshaft pulley. The pump shaft and bearing assembly is pressed in the water pump housing. The bearing is permanently lubricated during manufacture and sealed to prevent loss of lubricant and entry of dirt. The pumpis sealed against coolant leakage by a non-adjustable seal assembly pressed into the pumpcover.

Cooling water for the engine is picked up at the water intakes on both sides of the lower gear unit. Water is pulled upward thru the lower gear unit until it enters a water tube that transfers it to the upper gear unit. Water is pulled through the upper gear unit water passage where it meets a nipple and hose attached to the pivot housing. Water is routed through the transom shield assembly to a tube that’s mounted on the inside of the transom plate. From this tube the water is drawn through a supply hose that’s connected to the inside nipple of the raw=water pump. Water exits the outside nipple of the raw-water pump under pressure and carried through a hose to the inlet nipple of the thermostat housing. The water is now carried downwardthrough the thermostat housing where it enters the flexible hose which attaches to the inlet pipe of the circulating pump.This inlet pipe is a part of the pump cover and feeds the coolant into a low pressure area located at the axis of the impeller. Vaneson the rotating impeller cause the coolant to be thrown outward and into the cylinder block.

The cooling Water flows rearward through the water jacket which surrounds each cylinder and extends below the lower limit of piston ring travel. After flowing the full lengthof the cylinder block, the water is forced upwardthrough two passagesand into the cylinder head(s). Thewater nowflows forward in the cylinder head(s) cool the combustionchamberareas. At the forwardendof the cylinder head(s), the water enters the thermostat housing, if the water within the block is sufficiently warmedup, the thermostat will be openand a portion of the water will be pumpedupward past the thermostat. The remainderwill be returned via the flexible hoseto the water pumpfor recirculation within the engine block and heads. The water which was pumpedupward past the thermostat wilW enter the hose(s) connectedto the thermostat housing outlet(s) and travel to the manifold(s). At point the water flows rearwardthroughthe manifold passages andinto the high-rise elbow.All of the water that enters the high=rise elbowis mixed with the exhaust gases prior to entering the exhaust pipe(s) and hose(s). This mixture exhaust gasesand water then enters the exhaust passagesof the transom shield assembly,pivot housing and drive unit where it is discharged under water.

In the event the enginecooling water is cold, as in first starting up, the thermostatwill be closed and will not allow any of the water to pass through for eventual discharge overboard, instead, the water wilt be carried via the flexible hoseback to the circulating pumpfor recirculation within the block. Whilethe water within the bloclk is recirculating, the raw-water pumpis pumpingwater to the block. Since this water is not able to enter the cylinder block, it is necessary to provide a methodof discharge. This is provided by the bypasspassagewithin the thermos’tat housing, if this were not provided, the resullting water pressure would be enoughto force the thermostatoff its seat, resulting in a greatly increased warm-upperiod.

Cooling System Troubleshooting 1. Quiz Customer for the Following information: a. Howold is unit, how many hours of operation? (Wearand corrosion.) b. Howlong has problem existed? (Gradual or sudden.) C.

d.

Whatwere the operating conditions prior to problem?(Freshor salt water, silty or sandywater.) Whatprevious repairs and service have beenmadeon unit? (Tune-ups, impeller replacement,etc.)

e. At what RPMdoes problem occur? (Low, high.)

2, Possibilities That Must Be ConsideredFirst: a. Temperature GaugeMalfunction. ¯ ~mproper or defective sender unit ¯ Malfunctioning gauge - Checkground wire - substitute good gauge. b. Engine Water Circulation

PumpMalfunction.

¯ Loose alternator belt ® impeller vanes worn - replace pump. ® impeller shaft seal failure

- replace pump.

c. VVater Intake Screens Blocked. d. Ventilation - Marinegrowth on keel, huJl deformities, etc. e. ignition Timing ¯ Running with retarded timing - Check timing. 3. isolating Cooling Problem:

a.Procedure - Replace water hose between thermostat housing and the raw-water pump with clear plastic hose. Operateunit in test tank or boat in water at RPMat which overheat occurs. [~ If operating unit in test tank, run motor in neutral. Some test tanks maynot have sufficient water volume to allow running engine in gear without creating turbulence. This can be picked up by the water intake and misconstrued as evidence of a cooling problem. b. Results and Conclusions - No bubbles in hose, air/ exhaust is not entering cooling water. Bubbles in hose, air/exhaust is entering cooling water. c. Check for - Defective lower gear unit water tube guide and seals; damagedwater tube grommet; leaking water passage cover gasket; leaking impeller plate gasket or impeller housing O-ring.

9-4

Engine/eng

ao

Procedure - Disconnect water supply hose from thermostat housing. Operateengine at specified idle RPIVI. Hold end of hose level with the top of the engine. Results and Conclusions - A 2-4 inch (5-10 cm) head water discharge, water supply is good. If less than 2 inches (5 cm), look for source of water loss. Checkfor - Blocked intake screens; damagedimpeller housing O-ring or impeller plate gasket; broken or worn impeller; defective pivot housing water passage O-ring or water drain screw seal; loose pivot housing-to-gimbal housing water hose clamps.

a. Procedure - Operate engine until indicated temperature exceeds 160° . Touch hoses between thermostat and exhaust rnanifolds. b. Resuits and Conclusions - Hoses cold, thermostat is stuck closed. Hoses warmor hot, thermostat is good. c. Check for - Thermostat stuck open or closed, defective thermostat O-ring, correct thermostat style for engine type, clear thermostat housing bypass passage.

Procedure - Allow engine to cool. Replace water hose(s) between thermostat housing and exhaust manifold(s) with clear plastic hose. Operate unit at RPMat which overheat occurs. b°

ltesults and Conclusions - No bubbles evident, head gaskets not leaking. Bubbles evident, head gaskets leaking.

c.Check for - Cylinder compression using appropriate tester, water in engineoil, water in cylinders, spark plugs wet with water.

Volvo Penta Cooling System Problem Checkpoints for All Engine Modelsand SX Drive Units Numbersrefer

to Cooling System Flow Diagrams.

0 intake Screen - Baockedwith debris. (~ Water Tube Guide and Seal - nmproperiy sealed. (~ Water Tube - Plugged with debris. (~ Grommet- Deteriorated,

improperly seated.

C~) Upper Gear Unit - Debris blocking passage, freeze damaged. ~) Pivot Housing Seal - Damaged,out of position, sealed. ® Nipple O-ring - Out of position, aged.

improperly

improperly sealed, dam-

® Nipple - Blocked by debris, freeze cracked. ® Water Hose and Clamps - Clamps loose, hose collapsed or leaking. [~J TransomShield Water Tube - Blocked by debris. []

Raw-water Pump- Failed seal, corroded or bad bearings, eroded impeller, leaking mounting gaskets or backing pnate.

[]

Thermostat Housing - Corroded, restricted, ket.

[]

Thermostat - Defective thermostat, or wrong type for engine; improperly seated or damagedO-ring.

or leaking gas-

[] Belts- Loose, or worn and slipping. []

Circulating Pump(Engine) - Failed seal, corroded or bad bearings, eroded impeller, leaking mounting gaskets or backing plate.

[]

Cylinder Block Water Passages - Corrosion, slag, blocked passagesor leaking core plugs.

[]

Cylinder Head- Corrosion, slag, blocked passagesor leaking gaskets.

[]

Exhaust Manifold, Elbows, Gaskets and Hoses - Gaskets improperly installed; corrosion, sand or slag in manifold and elbows; hoses collapsed, burned through, or lea, king. Exhaust Pipe and Seal - improperly sealed or installed, leaking.

~]

Bellows, Clamp and Retainer - Loose clamp, detached or torn bellows. Engine and Power Steering cracked and leaking.

Oil Cooler - Restricted,

or

[] Intake Manifold - Crackedcasting, or leaking gasket(s). In addition, check: ¯ Ignition Timing ® Boat Hull - Condition of hull, hull equipment.

marine growth or ~Jnder-

l~ Fittings protruding through hull may cause air bubble streams which can be picked up by the lower gear unit and mixed with incoming cooling water to cause an overheat condition. For Duopropand DPXdrive units, refer to Duopropor DPX Workshop manuals.

® @

®

®

@ ®

~) From Transom Shield (E) Water Flow With Warm Engine © Bypass Passage Water Flow With Cold Engine

Mechanical Steering

@

®

|

Power Steering

\ Mechanical ,Steering Power Steering

@

®

@ 3.0 GS Modells DR4595 Engine/eng

9-9

® ® © ®

From Transom ShieJd Water Flow With WarmEngine Bypass Passage Water Flow With Cold Engine

@

@

4.3 Models(Carbureted}

@ DR5084

g-’l

0

Engme/eng

® ® © @

From TransomShield Water Flow With WarmEngine Bypass Passage Water Flow With Cold Engine

® \

@

_~)’~{~

5.0 and 5.8 FL Models

DR5085

4.3 and5.7 Gi

@

4.3 and 5.7 Gi Models

C~FromTransomBracket ,~ water Flow With WarmEngine (©BypassPassage @WaterFlow With Cold Engine DR5070

(A~ From TransomShield ® Water Flow With WarmEngine (~c~ BypassPassage ~ Water Flow With Cold Engine

®

5.0 and5.8 Fi Models DR5068

9-13

Engine/on~

® ® © ®

From Transom Shield Water Flow, WarmEngine Bypass Passage Water Flow, Cold Engine

/

@

®

® 7.4, 8.2 GL Models

7.4, 8.2 Gi, GSiModels Engirle/eng

9-15

Cooling System Components

For all models. No special tools required. inspection Procedure: Examineall external cooling system components for leaks, wear, deterioration, and damage.Check all connections for tightness. Inspect hoses for cracks, checking or deterioration. Repair Procedure: Repair or replace as required. Water supply hoses used for replacement must conform to S.A.E. 20R3, cmassD-2.

¯ All 3.0, 4.3, 5.0, 5.7 and 5.8 Liter Models: A 160° thermostat is standard. ¯ All 7.4 GL and 8.2 GL Models: A 140° thermostat is standard. inspection Procedure: Check for proper rating and style, sion, restricted movement,or broken spring.

corro-

DR3232

[~ [~ Test Procedure - All 3.0, 4.3, 5.0, 5.7 and 5.8 Uter Models: Immersethe thermostat and a thermometer in a container of water. Heat water. Thermostat should start to open between 157-163° F, and should open to %2 in. (3,96 ram) minimum(~ 182° F. ~-] Test Procedure: All 7.4 GL and 8.2 GL Mode|s: Immerse the thermostat and a thermometer in a container of water. Heat water. Thermostat should start to open between 138-142° F, and should open to %2 in. (3,96 ram) minimumbetween 140-162° F. °Thermostat . has full flow at 162 ¯ 3.0 GS Models rT] e All V-6 and V-8 Models Repair Procedure: None, replace unit.

E.Qi../e.~

9-16

DR3051

For all models.Nospecial tools required. Inspection Procedure: Pressure check componentsfor leaks. Disassemble and inspect for corrosion or accumulationof foreign material. Repair Procedure:Rod out any accumulation of foreign matter built up in water passages.If evidenceof porosity betweenwater passagesand exhaust chambersor exterior is found, replace component.Install newgaskets on reassembly.

For all models.Nospecial tools required. inspection Procedure:Makesure belt tension is correct. Wiith the engine running, observe the rotation of the circulating pump pulley. If the pulley doesnot run true it can causeexcessivedrive belt wearand damage to the circulating pumpitself. l’r the leakageof water occurs at the circulating pumpwhile the engine is in operation, the pumpmaybe loosely mountedto the engine, the shaft seal in front of the pumpmaybe bad, the backing plate gasket maybe defective, or the circulating pump mountinggaskets are leaking. If the aboveinspections do not detect any defect, the pumpmust be removedand inspected for internal corrosion, blockage, or damage,mnspectimpeller for erosion. Repair Procedure: None, replace the pump. Volvo Penta marine engines have a special circulating water pumpwith stainless steel components and a special marine shaft seal assembly. Do not replace with an automotive water pump.

9-17

Removal 1. Drainengine,refer to DrainingEngineBlockor ExhaustManifold. [~] 2. Loosenhose clampsand removehosesfrom raw-waterpump. Note:Theinside hose® is the inlet hose. 33857

[~ 3. Loosenpumpto bracket mountingscrews ® and removedrive belt. 4. Removemounting screws and removepumpassembly. Disassembly [~] 1 Remove the three screws© securing impeller housingto bearing housingand separate. [~ 2. To separateimpeller housingfrom bearinghousing,hold shaft while lifting andturning impeller housingcounter-clockwise.

33857A

[~ 3. if the impeller remainsin housing,graspwith pliers, pull and turn counter-clockwise. [~ 4. RemoveO-ring and discard. [~5. Removescrew and seal washer securing cam and remove cam.Refer to CleaningandInspectionbefore removingcam. [~ 6. Pull impeller fromshaft, if requiredandremove drive key@.

35349

[~] 7. Remove end plate andgasket. Discard gasket.

35350

9-18

~8

35362

r.~ 8. With a #1 retaining securing seal assembly.

ring pliers,

35363

remove retaining

35353

ring

~!~1 9. Removeceramic seal assembly. Do not attempt to disassemble further. The pulley, impeller shaft bearings and housing are serviced as an assembly. Cleaning and inspection 1. Clean all parts with solvent and blow dry thoroughly.

35354

2. Removeold gasket as required from end plate and bearing housing. 3. Clean O-ring groove and sealing surfaces. 4. Inspect impeller housing and camfor wear, and housing for cracks and distortion caused by freezing. Replace if necessary. Do not removecam if not required. 5. Inspect end plate; check impeller contact surface for wear, scoring or distortion caused by freezing. If only worn,-do not discard. Turn plate over and use other side when reassembling. 6. inspect

impeller;

if

blades are set in a bent position,

35356

cracked or

broken, or show flat instead of rounded edges on the housing contact surfaces, replace the impeller. 7. inspect ceramic seal surface for wear and cracks. Replace if worn or cracked. 8. Checkbearings ’for smoothoperation.

35357

9-19

Engine/eng

35358

35359

35360

Assembly [~] [~ 1. Install ceramic seal assembly. Secure by pushing retaining ring and seal assemblyonto shaft until retaining ring snaps into groove. Do not lubricate ceramic seal with grease. EEl 2. Install

drive key.

EEl 3. Apply a light coat of Gasket Sealing Compoundto the bearing housing gasket surface to hold gasket. Install end plate and newgasket. There is no orientation of the plate and gasket to bearing housing. DE] 4. Install

35354

impeller onto shaft and key,

EEl 5. if impeller housing cam was removed, install new seal washer on screw then apply Gasket Sealing Compound to threads. Position cam in housing; install screw and tighten securely. 6. Apply a light coat of Volvo Penta Grease to the impeller surfaces and O-ring groove of impeller housing. Install new O-ring seal. 7. install impeller.

impeller housing by rotating

35352

counter-clockwise onto

EEl 8. Orient impeller housing by rotating until assembly screw (~) next to the boss (E) is aligned with the mounting hole by cam screw © as shown. Install the three screws and washers, tighten securely. installation EEl 1. Orient pump assembly to the pumpbracket with the cam screw (~)up. Install mounting screws and belt. Refer to Raw-water PumpBelt Adjustment in the General information Section. 2. Attach the inlet hoseto the inside nipple and the outlet hose to the outside nipple. Tighten hose clamps securely,

35367

Removal 1. Drainengine,refer to DrainingEngineBlock or ExhaustManifold. E~ 2. Loosenhoseclampsand removehosesfrom supply pump. 42865

l Notei Theinside hose@is the inlet hose. E2~] 3. Loosenpumpto bracket mountingscrews ® and remove drive belt. Remove mountingscrews and removepumpassernbly. Impeller Removal [~ 1. Remove the three screws© securing the end cover. 2. Remove and discard gasket.

42864

E~3. Graspimpeller securely andpull from housing. Cleaningand inspection 1. Cleanall parts with solventandblowdry thoroughly. 2. Remove any old gasket from end cover and housing. Clean sealing surfaces. 3. Inspect impeller housingandcamfor wear, and housingfor cracksanddistortion causedby freezing. Replaceif necessary. Donot removecamif not required.

39149

4. Inspect endcover; checkimpeJlercontact surface for wear, scoring, or dEstortioncausedby freezing. Replace if necessary. 5. Inspectimpeller;if bladesare set in a bentposition,cracked,or broken, or showflat instead of roundededgeson the housing contactsurfaces,replacethe impeller. 39150

6. Checkbearingsfor smoothoperation.

39151

9 -

21

Engine/eng

39152

39154

39155

Impellerinstallation - V-6 andV-8 Models [~ 1. Apply a light coat of Volvo PentaGreaseto impeller surfaces.Install impeller until flush with surface. [~ 2. Install newgasket without sealant. 3. Install end cover and secure with screws. Tighten screwssecurely. 42865

Installation L3J 1. Orient pumpassemblyto the pumpbracket with the camscrew @up. install mountingscrewsand belt. Refer to SupplyPumpBeltAdjustmentin the GeneralInformation Section. 2. Attach the inlet hoseto the inside nipple and the outlet hoseto the outside nipple. Tighten hoseclampssecurely.

37902

23907

23913

Englne/eng

9-22

33857

22423

23913

Draining Engine Block or Exhaust Manifold Someservice work performedon the engine block and exhaustmanifold mayrequire the completedrainage of those components. Note iI All Fuelinjection Models Only:Drain the small water bypasshosebetweenfuel reservoir andthe top of the thermostathousing. Disconnecthoseat the reservoir side of the checkvalve. Blow out water in both directions. Inspect checkvalve for debris, then reassemble. 3.0 Models

28288

E~ 1. Removethe long supply hose at thermostat housing ®. Lowerit alongsidethe cylinder block anddrain it completely. [~] 2o Disconnectand drain large hose ® at water pump. [~ 3. Remove the drain plugs from cylinder block port side @and exhaust manifold ®. Clear holes with a small wire to ensurecomplete drainage. 4.3 and 5.7 Models

28287

[~ 1, Remove the long water supply hose at the thermostat housing C). Lowerit alongsidethe cylinder blockanddrain it completely. [~] 2. Disconnectand drain the large hoseat the water pump@. [~] 3. Remove hose ® from port at starboard exhaust manifolds. Remove drain ptugs (D on the port andstarboardsides of the cylinder block. Cleanholes with a small wire to ensurecompletedrainage. 24859

5.0 and 5.8 Models Remove the long water supply hose at the thermostat housing ~). Lowerit alongsidethe cylinder blockanddrain it completely. Disconnectand drain the large hoseat the water pump®. Remove hose @from the port and starboard exhaust maniRemove the drain plugs ® on both sides of the cylinder folds. block. Clear holes with a small wire to ensurecompletedrainage. 9-23 Engine/eng

24076

34161

28251

28283

[~ All Fuel injection ModelsOnly: Drain the small water bypass hose(~ betweenfuel reservoir and the top of the thermostathousing. Disconnecthoseat the reservoir side of the checkvalve. Blow out water in both directions, inspect checkvalve for debris, then reassemble. 7.4, 8.2 GLModels DE] 1. Remove the long water supply hoseat the thermostat housing ®. Lowerit alongsideblock anddrain it completely. 28284

2. Disconnectand drain the large hose at the water pump©u ~ 3. Removehose @at front of each port and starboard exhaustmanifold, and removedrain plugs <~ on both sides of the cylinder block. Clear holes with a small wire to ensurecomplete drainage. DrainingPowerStering Oil Coolers [~ Remove the lowest water hosefor the powersteering oil cooler. If oil cooler is mountedhorozontally, removeone water from the cooler ®. Loosenthe cooler mounting bracket @and tip cooler downward to drain.

15819

Draining Raw-WaterPump [~ 1. Loosenand slide hose clamps back. Removehoses from the rear of pumpanddrain. 2. Crank the engine no more than 2 seconds, (DONOTSTART) expel any water trapped in water pump.Reattach hoses. 33857

Draining Pivot Housing ~] 1. Tilt drive unit to the full tilt up position andremove the water drain plug ® from the port side of the pivot housing. 2. Tilt the drive unit to the full tilt down position.Allowunit to drain. After unit has completelydrained, replace pivot housingplug.

8--] 32351

/ J Failure to ensurecomplete drainageof the coolingsystem mayresult in seriousdamage to the engineand/ordrive unit if undrainedwaterfreezes.

Thermostat Replacement 3.0 Models [~ 1. Remove both water hoses(i) and alternator brace (,~ from upper thermostat housing. L~ 2. Takeout four mountingscrews and removethe upper thermostat housing.

14635

[~ 3. Remove and discard upper thermostat housing gasket, then lift out thermostat. Remove anddiscard cork seal ®. 4. Thoroughlyclean both gasket surfaces, then insert a new cork seal into housing. Donot apply sealer to cork seal. Install thermostat in housing with temperaturesensing element(D down. ’l~ 5. Coat both sides of a newgasket with GasketSealing Compound.Properly align the four screwholes and water bypassopening (~, then place gasket on housing.

14633

6. Install upperhousingandtighten four mountingscrewsto 5-7 ft. Ibs. (7-9 Nm). [’~ 7. Attach both water hoses® and alternator brace @.Tighten the hose clampsand brace mountingscrew securely.

32350

All GMV-6 and V-8 Models [~ 1. Removefour water hoses @from the thermostat housing. Note] For Gi and GSi Models, you must removefive hoses from the thermostathousing. [~ 2. Remove two screws®, and lifting stat housing.

eye, and lift

off thermo-

[~ 3. Thethermostat@is held in place by an O-ring. Pry the O-ring out of its groove,then lift the thermostatout of the housing.

28546

4. Discard the housing gasket and O-ring. Thoroughlyclean the housing and manifold gasket surfaces. 5. Place the thermostat in the housing. The temperature sensing element © must face you wheninstalled. Install a new O-ring to seal thermostatin housing.Makesure O-ring is completely seatedin its groove. 6. Coat both sides of a newgasket with GasketSealing Compound andplaceit on the manifold.Install the housingandlifting eyewith two screwsandlock washers.Tighten the screwsto 20--25 ft. Ibs. (27-34 N.m). 7. Connectthe water supply hose to nipple @and tighten hoseclampsecurely. Connectthe three remainingwater hosesand tighten hoseclampssecurely. Makesure lifting eye @is positioned as shown. -Note, If the water supply hose is attached to the wrongnipple, the enginewill overheat.

2854,7

9-26

Eng~ne/eng

All Ford Models 1. Remove all water hosesattached to thermostat housing. ¯ Carburetor Models: four hoses ®

rs]

¯ Fi and FSi Models: five hoses ®

[-6-]

E~] 2. All Models: Remove the two screws @and lifting lift off thermostathousing.

eye, and

[~] 3. The thermostat is held in place by an O-ring @. Pry the O-ringout of its groove,then lift thermostatout of housing.

22417

4. Discard housinggasket and O-ring. Thoroughlyclean the housing and adapter gasket surfaces. [~] 5. Place thermostat in housing. Thetemperaturesensing element® mustface you wheninstalled. Install a newO-ring to seal the thermostat in housing. Makesure O-ring is completely seated in its groove. 6. Coat both sides of a newgasket with GasketSealing Compoundandplaceit on the adapter.Install the housingwith two screws © andlock washers.Makesure lifting eye @is positionedas shown. Tightenthe screwsto 20--25ft. Ibs. (27-34N.m).

32348

. All Models E~] [~ 7. Connect water supply hose to nipple @and tighten hose clampsecurely. Connectremaining water hosesand tighten hoseclampssecurely. .......Note ~lf the watersupplyhoseis attachedto the wrongnipple, the enginewill overheat.

2241

14649

|:’ngine/eng

9-27

NOTES

Section 10 Engine Removaland Installation Volvo Penta SX Models Table of Contents Engine Alignment ..................................... Installation .................................... Removal ...................................... Determining Minimum Engine Height ................. Engine Mounts, Rear .............................. Exhaust Pipe Replacement ..........................

10-7 10-6 10-2 10-12 10-11 10-6

VolvoPentaSpecial Tools PIN 3851083-0 3850609-3

Description Volvo Penta Alignment Tool Volvo Penta Drive Handle

Sealants, LubricantsandAdhesives Volvo Penta Grease 3M adhesive or equivalent Gasket Sealing Compound

L~ Safety Warnings Before beginning work in this section, r,sad Safety chapter at end of this manual. Proper installation is important for the safe, reliable operation of all mechanical products. The procedures we recommend and describe in these instructions are effective methodsto be followed when installing Volvo Penta SX stern drive products. Some of these methods require the use of tools specially designed for the purpose. The special tools should be used when and as recommended.

EngineRernoval Before removing engine, check engine height. See Determining MinimumEngine Height. Check engine clearance between front of engine and engine compartmentbulkhead prior to starting work. if clearance is less than 6 in. (15,2 cm), the drive unit must be removedto disengage U-joint shaft from engine coupler. See Drive Unit and Transom Shield WorkshopManual. Whenengine clearance is more than 6 in. (15,2 cm), the engine can be pulled forward to disengage the U-joint shaft from the flywheel coupler, and be removed from the engine compartment.

22703

[~ Drive can remain installed only if engine removal does not require disturbing engine mount height, and engine crankshaft is not rotated. If mount height would need to be changed, or driveshaft/coupler splines becomemisaligned because of crankshaft rotation, removedrive also. ,/~ To prevent possible fire and expJosioncausedby ignition of fuel vapors which maybe present in the engine compartment, removethe positive and negative cables from the battery.

22704

Battery Disconnection ~,~ Disconnect the red (positive) end black (negative) cables at the battery. [~ The key switch must be in the "OFF" position to safeguard against permanent damageto electrical components while connecting or disconnecting the battery cables. Power Steering Line Disconnection [~ 1. Disconnect both power steering cylinder.

lines

at the steering

22706

~ 2. If original steering line connector is available, use it to link both steering lines together. If Connectoris not used, cover both steering cylinder openings and line fittings to prevent fluid loss and entry of contaminants. Tie lines onto engine higher than power steering pumpto prevent damageand loss of oil during engine removal. Fuel Supply Disconnection [~ ~ Disconnect boat fuel line at the fuel filter of fuel line and inlet opening. Electrical

inlet.

SeaJ end ~ ¯ ,i

Cable Disconnection

[~ 1. All Mode|s: Disconnect the plastic two-wire trim/tilt connector(~).

Safety Related

2913

10-2

motor

31461 Engine/eng

33727

31460

L~ 2. Removewire retainer ® and unplug rubber two-wire trim/ tilt senderconnector.Cut tie strap © securingsendercable, if required. ["~""’~[~] 3. Unscrewclampand disconnect large rubber instrumentcable connector@. Unplugrubber three=wire trim/tilt cable c, onnector®. All modelsexcept MPI,removereceptacle from electrical bracket. ¯ Carburetor, Gi, and GSi Models ¯ Fi and FSi Models

E! E~l [~

Throttle CableDisconnection

®

29790

®

[-~ [~ 1. Removecotter pin and fiat washer ® or lock nut @ from throttle arm. [~ 2. Loosenanchorretainer nut ® and rotate retainer (~) awayfrom cable trunnion. Remove throttle cable from throt:le arm and anchorbracket. ¯ Carburetor, and TBi, Models - Fi and FSi Models , 7.4, 8.2 Gi, GSi Models

O

OR497~

~1 ~1 ~J

DR4980

ExhaustHoseDisengagement - 3.0 Models E~ 1. Loosen four hose clamps. DE] 2. For ease of movinghose, lubricate exhaustpipe. [~ 3. To free exhausthose from elbow, pry or twist hose. Slide hose downonto exhaust pipe. ExhaustHoseDisengagement - A|| V-6 and V-8 Models [~ 1. Loosenfour clamps~) on lower exhaust hose. For ease of movinglower hose, lubricate exhaust pipe.

6361

2. To free lower hose from intermediate pipe, pry or twist hose. Slide hose downonto exhaust pipe (~.

6362

6363

17370

10-4

~737~

Engine/eng

Water Hose Removal J~-] Loosen dampand pull water supply hose offtransom shield water tube. Engine Mount Separation ~ 1. Attach a hoist to lifting brackets of engine. Hoist must havea lifting capacityof at least 1500Ibs. (680 kg). 2. Removeand retain both lock nuts © and both flat @from rear engine mounts.

washers

I~ ~ 3. Remove and retain mounts.

engine

lag screws from front

22698

e 3.0 Models [~ ¯ All V-6 and V-8 Models 4. If drive unit was removed, lift engine out of engine compartment. If drive unit was not removed,lift engine slightly and pull it forward to disengage U-joint shaft and flywheel coupler. With U-joint shaft clear’ of flywheel coupler, lift engine out of compartment.

33959

12211

2888

Engineleng

~ Safety Related

10-5

2933

Exhaust Pipe Replacement Removal 1. Removeengine following

previous procedure.

[~ 2. Remove and retain four exhaust pipe screws. Remove exhaust pipe and discard seal (~). Clean all material from transom shield and exhaust pipe seal surfaces. Exhaust pipe mounting holes have locking Hell-Coil® inserts. Do not clean screw holes with a thread tapping tool, otherwise locking feature will be destroyed and Heli-Coflwill have to be replaced.

22780

Installation 1. Coat a new seal with 3M adhesive or equivalent and place in transom shield groove ®. [~ 2. Apply Gasket Sealing Compoundto the four exhaust pipe mounting screws ©. I~] 3. Secure exhaust pipe (~) to transom shield with four screws. Tighten to 20-25 ft. Ibs. (27-34 N-m). Slide exhaust hoses and clamps (~) onto exhaust pipes if they were removed.

15048

4. Install engine.

EngineInstallation Engine Mount Attachment 1. Lower engine into engine compartment: if drive unit was not removed, and engine crankshaft was not rotated, engage U-joint shaft with engine coupler and slide engine back onto rear mounts, if coupmerand U-joint shaft will not align, either the engine or U-joint shaft will have to be rotated to allow engagement. If engine mount height was disturbed, engine must be realigned as described later.

15047

¯ if drive unit has been removed, lower engine onto rear mounts. 2. Install flat washers® into recesses of engine bracket and secure engine to mount with lock nuts (~). Tighten lock nuts 28-30 ft. Ibs. (38-40 N-m).

~2212

[~ I-~ 3. install themsecurely.

forward engine mountlag screwsand ’tighten

¯ 3.0 Models

= =

¯ All V-6 and V-8 Models If drive unit was not removed,go on to Exhaust HoseAttachmont. If drive unit wasremoved,continue with EngineAlignment section.

m

Engine Alignment

2888

[~ Correct engine alignment is essential to long engine drivetrain life. The front engine mountsmayneedadjustment UPor DOWN to produce correct engine alignment. Use Volvo Penta Alignment Tool P/N 3851083-0with Volvo Penta Drive HandleP/N 3850609-3to check engine alignment. ~-~ 1. Slide alignment tool ® through driveshaft gimbal bearing ~. Thealignment tool must slide through the gimbal bearing and into engine coupler with ease. If the alignmenttool binds going into engine coupler, makesure the gimbal bearing is properly aligned. If gimbalbearingalignmentis correct, the front ,engine mountsmust be adjusted either UPor DOWN, as required, until alignmenttool slides easily in and out of enginecoupler.

2933

~] ~1 2. To changeengine height, tighten or loosen nuts (~) and (~) as required. Seerespective engine section, Front Mount Height Adjustment. ¯ 3.0 Models [~ ¯ All V-6 and V-8 Models [~ 3. After correct alignment has been made,the front mount(s) =mustbe tightened to maintain alignment.

34O6O

3.0 Models - While holding one nut with an open-end wrench,tighten the secondadjusting nut to a torque of 115-140ft. Ibs. (156-190N-m). e

V-6 and V-8 Models - While holding one nut with an open-endwrench, tighten the secondadjusting nut to 100-120ft. Ibs. (136-163N-m).

2972

i 10 Engin~en9

10-7

2953

Exhaust Hose Attachment El 3.0 Mode|s - Slide exhaust hose (~ up onto high-rise exhaust elbow ®. V-6 and V-8 Models - Pushlower hoses (~) up onto intermediate exhaust pipes (~. E~ Position and tighten all hose clamps securely between ribs of exhaust hose(s) as shown. E~ ~ Do NOT install hose clamps in expanded area (~ of hose(s)= Cooling will be restricted and engine damage will occur.

2945

Throttle Cable Installation Move remote control handle to the NEUTRALdetent position, Turn propeller shaft and shift into the forward gear detent position, and then pull HALFWAY BACKtowards NEUTRAL.This positions the control for proper throttle cable adjustment. Failure to follow this procedurecan bind the shift linkage in the control, and produce hard shifting. r~ 1. Align internal bosses ® of trunnion with throttle groove (~). Press trunnion on throttle cable until seated.

cable

17372A

Engine anchor bracket may have two sets of anchor block holes. The top set is for the 4V (4 barrel) carburetor models, and the bottom set is for the 2V (2 barrel) carburetor models. E~ z~ 2. Install open end ~) of trunnion in anchor block. Install screw in anchor block and position throttle cable assembly in selected set of holes. Nut (~ mustbe against the anchorbracket, tighten it securely. [~ ~ 3. Throttle arm connector (~) must have a minimumof full turns or 1/4 in. of throttle cable thread engagement, Instaim throttle arm connector onto the throttle cable. Pull connector forward (~) to removeall end pJay from throttle cable, then turn the connector in until hole aligns with the throttle arm (~.

17370A

®

[~ If throttle arm connector hole cannot be adjusted to align with the throttle arm, check for proper cable installation in the remote control box.

34751

Safety Related

10-8

DR4978

DR4979

DR4980

[’~ ~ 4. Carburetor, Gi and GSi Models: Install connector onto throttle arm. Install washerand cotter pin ©, andspreadcotter pin prongs.Tighten jam nut ~) against connector. DE] ~ 5. Fi and FSi Models:Install connectoronto throttle arm. Install and tighten throttle armIocknut®. Tighten jam nut against connector. ! Note l For throttle and shift cable adjustmentprocedures,see Throttle andShift ControlSystems section.

22698

WaterHoseinstallation r.~ 1. Slide hoseclamp@onto water inlet hose. Lightly lubricate inside of water inlet hoseandpushhoseonto water inlet tube ®. [~ 2. If inlet hoseis not installed properly, undersideof hosemay collapse. Checkundersideof hosefor properinstallation s:nd adjust hoseas required. Tighten hoseclampsecurely. N°te=iFailure to install waterinlet hosecorrectly canresult in engine damage from blockageof water circulation.

15864

PowerSteeringLine installation 1. Remove tape or protective cover from small hydraulic hosefitting (or unscrewsteering line connector)andsmall steering cylinder opening. [1~ 2. Install smat/Ihosefitting into steeringcylinder andtighten to 10-12ft. Ibs. (14-16N.m). 22702

3. Remove tape or protective coverfrom large hydraulic hosefitting andlarge steering cylinder opening. L~4. Install large hosefitting into steering cylinder andtighten to 15-17ft. Ibs. (20-2!3N.m).

m

12 s~i.~o,~ ~ Safety Related

10-9

22701

24208

33730

Electrical Cable Connections [’~ 1. Connectplastic two-wire plug of engineharnessto two-wire receptacle@of trim/tilt motor. Connectorsshouldlock together. [~] 2. Connectrubber two-wire trim/tilt senderplug to two-wire receptacle ® of instrument harness. Secureconnectorswith wire retainer andcable with a tie strap @. 3. Routethe instrumentcable plug to join enginecable receptacle

33727

on engine.

L~ Ensurecable is routed to prevent cutting or chafing on any sharpor hot object. This couldresult in an electrical short, andcontribute to fire andexplosionin the enginecompartment.

EEl4. Carburetor, Gi, and GSi Models:Routetrim/tilt

cable behind shift bracketandinstall plug @into electrical bracket. 5. Apply a light coat of Volvo PentaGreasearoundlarge engine plug(~). DE] 6. Align the marksof the trim/tilt and press together.

29790

plug and receptacle F

¯ Carburetor, Gi and GSi Models

[~

¯

E~

Fi and FSi Models

E~ [~ 7. Slide hose clamp over large engine receptacle. Align the two large terminals on plug and receptacle @and press together. Slide hoseclampover receptacle and tighten securely. ¯ Carburetor, Gi and GSi Models - Fi and FSi Models

3146O

[~ [~]

~8. Modelswith Starter Solenoids:Position the red cable protector over solenoidterminal. 9. Makecable connectionsat the battery. Be sure polarity is observed;positive (+) cable to the positive terminal, andnegative(-) cable to the negativeterminal. Safety Related

10-10

Fuel Supply Connection Attach boat’s fuel supply hose to fuel filter canister. Tighten connectionsecurely, Checkfor fuel leaks whentesting engine, and repair any leaks that might occur.

Rear Engine Mounts Removal 1~. Removeengine as previously described in this section. 6678

2. Unscrewtwo screws and washers, then lift bly off transomplate.

mount assem-

Disassembly [~] Hold square nut and remove screw. Mount assembly will break down into componentsshown. Pay particular attention to the two mount washers; their thickness, their shape (concave or fiat) and their position in the assembly(above or below the rubber mount). Assembly

16348

L’~ 1. Slide lower washer ® onto mount bolt; make sure you choose the correct washer (as determined during the mount disassembly)for this position, insert bolt into bottom (flat) side rubber mount assembly, and install remaining washer and square nut. Do not tighten nut at this time. If top and bottom washersare not installed in their original positions, mount may transmit excessive engine vibrations into boat and cause undesirable operating conditions. [~ 2. Turn mount assembly upside down and clamp square nut in vise. Rotate rubber mountuntil mounting holes are posil:ioned at 90° to any side .of square nut. Hold mountin this position and tighten center bolt to 44-52 ft. Ibs. (60-71 N-m).

6680

if 900 relationship between nut and mounting holes is not maintained, slot of engine mount pad cannot engage rear mount during installation. Installation D"~ 1. Place mount assembly on transom plate, install two screws and washers, and tighten them to 20-25 ft. Ibs. [27-34 N-m). 2. Install engine as previously described in this section. Makesure mount pad slot engagessquare nut. install both fiat washers and lock nuts, then tighten lock nuts to 28-30 ft. Ibs. (38-41 N.m).

6677

® ©

DR4960

Determining MinimumEngine Height r~ 1. To determine minimumengine height, use a level ~) placed on top of the transom,measurefrom bottomof level to top of elbow ® and record distance. 2. Measurefrom bottomof level to static water line © and record distance. I~ 3. Subtract dimension (~ from dimension © and record result. Seeengine height requirementsbelow: ® 3.0 Models - Measurement© minus @should not be less than 9 in. (22,8 cm). e V-6 Models - Measurement© minus ® should not be less than 13 in. (33 cm). ¯ V-8 Models - Measurement© minus (~) should not less than 14 in. (35,6 cm). 4. Whenengineinstallations do not meetthese specifications, an exhaustelbowhigh-rise kit mustbe installed. An installation that permits water to enter the engine through the exhaustmanifolds(s) will not be coveredby warranty, unlessdamage is dueto defective part(s).

Safety Section

Part A Marine Products and Safety of People Who Use Them . . . . . . . . . Sterndrive Shift System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sterndrive Throttle Control System . . . . . . . . . . . . . . . . . . . . . . . . Sterndrive Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sterndrive Fuel, Electrical System . . . . . . . . . . . . . . . . . . . . . . . . .

S-2 S-3 S-4 S-5 S-7

Part B Marine Products and Safety of People Who Fix Them . . . . . . . . Handling Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling Lead Acid Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline! Handle with Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hazardous Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety

S-1

S-11 S-11 S-12 S-13 S-14

Part A - Marine Products and safety of People Who Use Them

Enjoyable boating is the goal of people who design and build marine products. To reach this goal, manufacturers are careful to make sure... Product User is informed. . . Products are safe and reliable. . . It's up to you, the People who. . . Install accessories. . . Service and Maintain the boat. . . Service and maintain the sterndrive. . . . . . to keep the products safe and reliable. This section talks about safe boating and how you can help keep it safe. Some things you may know . . . but others you may not.

First! A word about fasteners . . . plain . . . special . . . all screws, nuts, washers and bolts.

Do Not Substitute Fasteners

They look the same, but . . . are they? The Same Size? The Same Strength? The Same Material? The Same Type? Standard or Metric Thread?

Don't substitute unless you know they are the same in all characteristics. Second! Special locking screws and nuts are often used to attach steering, and remote control components to the sterndrive. When you remove any part from the sterndrive, keep track of special screws and nuts. Don't mix with other parts When reassembling the sterndrive, use only the special screws and nuts intended to hold steering, and control cables, plus related parts. Service with parts of known quality that meet Marine Industry (BIA/ABYC) Standard.

S-2

Safety

Sterndrive Shift System

The Shift System starts here at the remote control lever. . .

. . . and ends here at the propeller.

What's Most Important? When the control lever is in Forward, Neutral or Reverse position . .

. . . Shift mechanism must match control lever position.

What Could Happen? If . . . Neutral

If . . . Forward

Forward or Reverse Reverse

. . . Propeller is still powered (turning) unknown to operator, or engine will start in gear, boat will move unexpectedly.

. . . boat will move opposite to direction intended by operator.

How Can Loss of Shift Control be Minimized? In pre-delivery inspection and when servicing . . . Read, understand and follow manufacturers instructions. Closely follow the warnings marked with

...

Assemble parts and make adjustments carefully . . . Test your work. Don't guess. Make sure propeller does what the operator wants and nothing else. Safety

S-3

Sterndrive Throttle Control System

The throttle Control System starts here and the remote control lever . . . . . . and ends here on the engine.

What's Most Important?

When the control lever is moved from Forward (or Reverse) to Neutral . . .

. . . engine speed must slow to idle RPM and allow operator to shift into Neutral.

Operator must be able to stop propeller. What Could Happen? If operator cannot slow the engine to idle RPM and shift into neutral, (stop propeller), operator could panic and lose control of boat.

How Can Loss of Throttle Control be Minimized? In pre-delivery inspection and when servicing . . . Read, understand, and follow manufacturers instructions. Closely follow the warnings marked with

...

Assemble parts and make adjustments carefully . . . Test your work. Don't guess. Make sure engine throttle response is smooth. Make sure full throttle operating RPM can be reached so operator won't overload engine

S-4

Safety

Sterndrive Steering System

The Steering System starts here at the helm . . .

What's Most Important? The Steering System . . .

. . . and ends here at the propeller on the sterndrive

must be installed properly must be adjusted properly must be lubricated

What Could Happen? . . . if steering system comes apart, boat would turn suddenly and circle . . . passengers and/or operator may be thrown into water and could be hit.

. . . if steering jams, operator may not be able to avoid obstacles. Operator could panic. . . . if steering is loose, operator may not be able to maintain a true course, and could result in loss of boat control.

Safety

S-5

How Can Loss of Steering Control be Minimized? In predelivery inspection and when servicing

use steering components which meet marine industry (BIA/ABYC) standards . . . Read, understand, and follow manufacturer's instructions. Assemble parts and make adjustments carefully . . . Closely follow the warnings marked with ... Keep parts moving freely . . . lubricate parts as soon as shown in manuals Use bolts, nuts, and washers supplied with steering attachment kits

When power assisted or mechanical steering systems are used, check to uncover possible trouble! Cable housing in this area must not be restricted

Steering components must not bind

Why? Unit may go to full turn without turning steering wheel (Power assist models)

Why? Possible jamming of steering system.

Engine stringer must not interfere with power steering pump and pulley

Maintain proper belt tension. Power steering parts and push/pull cable must be free to move in order to actuate power steering valve when operator turns steering wheel

Check for damaged parts . . . impacts to the sterndrive like this

or this . . . or ? ? ? can put stress on steering components. Look for . . . Cracked parts Bent parts Loose fasteners

Replace damaged parts. If weakened, parts could fail later . . . on the water . . . when least expected. S-6

Safety

Sterndrive Fuel and Electrical Systems

The electrical System begins here at the battery . . . . . . and ends here at the carburetor or fuel injectors

The fuel system starts here at the fuel tank . . .

. . . and ends here on the engine.

What's Important? Fuel leakage must be prevented. Electric sparks must not happen.

What Could Happen? Gasoline can explode and/ or burn easily: When boating, fuel leaking in the engine compartment could be ignited by a spark from a loose wire connection, or a damaged or deteriorated electrical component.

How Can Fire and Explosion Be Minimized? Read, understand and follow manufacturers instructions. Closely follow the warnings marked with

...

Do not substitute fuel or electrical parts with other parts which may look the same. These parts are designed and manufactured to meet special U. S. Coast Guard safety regulations to prevent fire and explosion. If you work on marine engines, you must understand these U.S. Coast Guard requirements. If you don't have them, write to . . . ------------------------National Technical Information Service Springfield, Virginia 22161

. . . and ask for copies of: (1) Electrical System Compliance Guideline (AD/A-049-638) (2) Fuel System Compliance Guideline (AD/A-047-767) These are concise guidelines - easy to read and understand. They explain what must be done to prevent fire and explosions. Safety

S-7

Always use replacement parts specified by the manufacturer. They meet the U.S. Coast Guard requirements. Most automotive parts do not, especially electrical components that must meet ignition protection requirements of the U.S. Coast Guard regulations. When nonmetallic parts look to be in poor shape . . . replace them!

Wires Cracked!

Torn Boots!

Cracked Fuel Lines! Using parts which meet U.S. Coast guard requirements is only half the job. The other half is your job . . . It's time for replacement BEFORE sparks and/or fuel leaks occur. Replace parts carefully. Make sure nuts and bolts are tight especially when they anchor electrical wires (to prevent sparking). If lock washers are specified - use them. No short cuts or missing parts with either of these CRITICAL safety related systems. When refueling, always ground fuel nozzle to the inlet fitting on the boat to prevent the buildup of electrostatic sparks. If you use a funnel, make sure it's metal and ground the fuel nozzle to the funnel.

STOP

If you smell gasoline in the engine compartment . . . find its source and stop the leakage.

S-8

Safety

Follow "Starting Procedure" outlined in the operator's manual. Always make sure there are no gasoline fumes in the engine compartment before starting the engine. Open the compartment and use your nose. Don't gamble. Backfire flame arrestor must be in place and securely attached to the air intake.

Do not alter the backfire flame arrestor. If loose, damaged, or altered, an engine "backfire" may pass through the flame arrestor assembly into the engine compartment. If fumes are present in compartment, fire and explosion could result.

Safety

S-9

Summing Up Now you know some things that can take the joy out of enjoyable boating. No doubt about it . . . it takes time! Reading and understanding instructions. Reading and understanding warnings marked with

...

Putting parts together correctly . . . Making correct adjustments . . . Testing you work.

and making sure Worn or damaged parts are replaced, Replaced parts are like originals . . . in every way. Customer is told of things which need attention . . .

But do you really want the alternative?

S-10

Safety

Part B - Marine Products and Safety of People* Who Fix Them

Part A talked about safe boating and how you, the mechanic, can help keep it safe for the boater. But what about you? Mechanics can be hurt while . . . Servicing boats Servicing sterndrives Troubleshooting problems Testing their work Some items you'll know . . . others you may not.

When Lifting Engines If hoist is poor shape . . . or too small for the job Engine may drop suddenly

DR3471

DR3469

Make sure shop aids have extra capacity — and keep them in good repair!

When Running Engine with Engine Compartment Cover Removed The engine compartment cover is a guard. When you remove the cover / guard to work on the engine, remember: Loose clothing (open shirt sleeves, neckties), long hair, jewelry (rings, watches, bracelets), hands, arms, belts can be caught by moving belts or spinning pulleys Handle high voltage ignition components carefully. They can shock you and may cause you to recoil into moving parts. Two people working together on a running engine must look out for each other. Never, ever, hit the key to start the engine before signalling to your partner. (He may be leaning over the engine with his hands on a belt, or a "hot" electrical part, near the propeller, etc.) *Mechanics, technicians, backyard do-it-yourselfers.

Safety

S-11

Exhaust gasses of running engines contain carbon monoxide. . . you can't see it. . . you can't smell it. . . you can't taste it. . . but it's there whenever an engine runs. . . and it's deadly! When you smell the other gasses in the exhaust, you are inhaling carbon monoxide. Run engines only in well ventilated areas.

Eyes Need help

Grinding

Sprayed Cleaners, Paints

End of Cables

Acid

Chiseling (steel on steel) (Tip: Use plastic or brass type hammers. They don't chip off as easily as steel hammers.)

Handling Lead Acid Batteries

If spilled or splashed on any part of body..

Wash with lots of water. . .

If solution gets into eyes. . . Wash. . . and see a Doctor, fast!

Charging Lead Acid Batteries Attach and remove these cables with charger unplugged from 110 volt wall socket. (Prevents shocks if the charger is defective.) Observe correct polarity when connecting these charger leads. Always charge in a well ventilated area. Charging causes acid solution to give off hydrogen gas through the vents in the caps. . . Make sure vents are open. If clogged, pressure inside may build. . . battery may explode.

S-12

Safety

Never yank cables off battery posts. . . it's a sure way to make lots of sparks. . .surrounded by battery gas

Battery gas is explosive! While charging or discharging, remember. . .

No Smoking No Flames No Sparks

After Charging. . .

Don't check battery condition by placing metal objects across posts.

Shut off charger Remove charger plug from wall socket Then. . .

You're sure to make sparks and serious burns are possible.

Take charger cable off battery posts

Gasoline! Handle With Care When you smell any odor of gasoline, explosion is possible Gasoline fumes are heavier than air and will sink to the lowest point in the boat or room, and will stay there. . . waiting Gasoline explodes easily and violently when mixed with air

If the air around you is quiet . . . the pilot light in the heater may ignite the heavy fumes before your nose ever smells the fumes . .

5 Parts Gasoline 100 Parts Air

What Can you Do?

Store in sturdy, sealed gas can . . .and . . . keep outside Safety

Store properly . . . Fill portable tanks outside boat to prevent spillage in boat Use fuel for fuel . . . not for a solvent If fumes are smelled (in shop, basement, garage), immediately: Put out open flames, cigarettes, sparking devices Wipe up spill or leak; get towels, rags outside fast Check lowest area for fumes; open doors or windows

S-13

Know items in and around repair area which can ignite gasoline fumes . . . Control them if fumes are smelled. Matches, cigarettes, torches, welders Electric motors (with unsealed cases) Electric generators (with unsealed cases) Light switches Appliance pilot lights (furnace, dryer, water heater) ????????? How many of these are in your area?

Hazardous Products

Read the container label. It tells you . . . "How, and where, to use," "How to give First Aid," and have "recommended" first aid materials on hand- should an emergency arise "How to dispose of can," Remember: Little children are very curious and will try to taste everything, so . . . Keep containers away from children

. . . yummmmmmmmmmm

S-14

Safety

VOLVO PENTA MODEL iDENTiFiCATiON Engine Modelidentification is located on the engine valve cover for four cylinder (in-line) models, on the inside of the port valve cover for V6 & V8 models, or on the Thick Film Ignition (TFI) modulebracket for Ford fuel injection models. The identification numbersmust correspond with the transom shield and drive unit numbers. See below.

Engine Model Number(GL, GS, and Gi Models) Engine Model Number(Fi Models)

SX MODELS: [~ [~

Transom Shield Model Number Drive Unit Model Number

DP & DPX MODELS:

Nunber plate for drive unit andtransom shield. Onlyfields 2 and3 arefilled for transom shield.

4

1 3 1. ProductDesignation 2. Model Number 3. Serial Number 4. ReductionRatio