Mercury MerCruiser Engine Removal

[Dax68]

Hello Everyone,

I am new on the forum, also new to working on boats. I have ample knowledge on cars and truck engine and trans works along with all other car issues. Here is the details on the boat and project i am planing to do any help or guidance would be greatly appropriated.

1983 Searay with Mercury MerCruiser Sterndrive engine MCM 228 5.0 L

I need to pull the engine out to replace flywheel and starter. I have all area cleared and ready for engine to be pulled out have 2 ton hoist on site.

I need help in following. Once the engine is ready to be lifted with 4 bolts i ma planning to remove the sterndrive. Do i need to do anything prior to removing the drive?

Once the engine is out anything i need to be careful about changing the flywheel ?

I am familiar on changing flywheels on cars.

Also once the replacement is done i do understand i need to use the tool to align the engine correctly. Any advise on which tool to order from eBay ?

Do i need to change any seals or gaskets prior to installing back the driveshaft ?

If there is any step by step info on removal of engine it would be great.

Thanks in Advance.

 

[Scott Danforth]

first, welcome aboard

second, you dont need a flywheel, you need a $15 ring gear

the flywheel on your motor is the exact same flywheel from a 1983 truck with a manual transmission.

you need the alignment tool. you need that for your annual alignment inspection

prior to pulling the drive, make sure its in forward.

look at the videos in the stickies

step by step is covered in the manual.

however pull the drive
disconnect the battery, exhaust, fuel, cables, and big harness connector
remove the two rear mount bolts
remove the two front mount bolts
lift

 

[harringtondav]

While you have your engine pulled you'll have a rare opportunity to inspect and repair other things. Especially in a boat that age. My first interest would be the condition of the transom and front engine mount structure. A drill and an oscillating cutting tool will tell you a lot. Some other things to consider are replacing the rear engine mounts. There are more that you could run into. Keep the forum posted. It's a gold mine of know-how.

 

[achris]

.... Once the engine is ready to be lifted with 4 bolts I am planning to remove the sterndrive...

Drive MUST be removed BEFORE the engine is lifted... (It's usually the very first thing I do)

Chris....

 

[Dax68]

first, welcome aboard

second, you dont need a flywheel, you need a $15 ring gear

the flywheel on your motor is the exact same flywheel from a 1983 truck with a manual transmission.

you need the alignment tool. you need that for your annual alignment inspection

prior to pulling the drive, make sure its in forward.

look at the videos in the stickies

step by step is covered in the manual.

however pull the drive
disconnect the battery, exhaust, fuel, cables, and big harness connector
remove the two rear mount bolts
remove the two front mount bolts
lift

Thank You Scott for your input. I had acquired the new flywheel from buddy of mine who closed his mechanic shop and he use to service lot of GM trucks back in day.

I ordered the tool from eBay for alignment.

Will follow the steps you listed and watch all the videos as you suggested.

Again Thanks for your reply.

 

[Dax68]

While you have your engine pulled you'll have a rare opportunity to inspect and repair other things. Especially in a boat that age. My first interest would be the condition of the transom and front engine mount structure. A drill and an oscillating cutting tool will tell you a lot. Some other things to consider are replacing the rear engine mounts. There are more that you could run into. Keep the forum posted. It's a gold mine of know-how.

Thank You harringtondav,

Will do as you suggested and keep you posted.

 

[Dax68]

Drive MUST be removed BEFORE the engine is lifted... (It's usually the very first thing I do)

Chris....

Chris,

Thanks is my plan. Thanks

 

[Dax68]

Hello Everyone.

Following was done and completed today.

* Took the engine out
* Replaced the new flywheel
* New Mercury starter was installed
* Check the Transom - All good no issues.
* Check all 4 mount and all structure area - all good no issues.
* changed the engine oil and oil filter
* All new spark plugs
* Align the Engine perfectly
* Use all new gaskets and install the out-drive.
* Rebuild the Carb

Here is the issue.

Few cranks and boat started fine. Ran for 20 min. No over heating issue. Turn the engine off. Can't start it back. It cranks but would not fire up.

I though rebuilding the carb will resolve any flooding issues. Does this engine has any heat switch or any related issue so when the boat is hot it is not starting.

I am clueless at this point and have no clue what to do. Any help would be appreciated.

Thanks

 

[Rick Stephens]

You have worked on car and pickup motors, this is quite literally no different. An '83 motor has no overheat shutdown, any more than your old '83 Chevy pickup did. Most all of the motor is the same as in that '83 pickup. Sure, all the external parts are marinized to make them safe running inside a closed space where fumes cannot escape. But in all other ways, the task in front of you is the same as in the pickup.

If it won't start, pull a plug and see if it is flooded or dry.

Use a $12 Spark Gap Tester to see if you have spark.

If the carburetor hasn't been touched in years, assume it needs a rebuild.

Use the Mercruiser Service Manual to accomplish all your tasks. You can read them online at www.boatinfo.no


If this is a new to you boat, you need to go through all the scheduled service items that the previous owner has been skipping for years. And pump some fuel out into a glass container and see if it is still clean gas or starting to turn into crap.

 

[Dax68]

You have worked on car and pickup motors, this is quite literally no different. An '83 motor has no overheat shutdown, any more than your old '83 Chevy pickup did. Most all of the motor is the same as in that '83 pickup. Sure, all the external parts are marinized to make them safe running inside a closed space where fumes cannot escape. But in all other ways, the task in front of you is the same as in the pickup.

If it won't start, pull a plug and see if it is flooded or dry.

Use a $12 Spark Gap Tester to see if you have spark.

If the carburetor hasn't been touched in years, assume it needs a rebuild.

Use the Mercruiser Service Manual to accomplish all your tasks. You can read them online at www.boatinfo.no


If this is a new to you boat, you need to go through all the scheduled service items that the previous owner has been skipping for years. And pump some fuel out into a glass container and see if it is still clean gas or starting to turn into crap.

Rick,

Thanks for your reply and advise. I have just rebuild the carburetor this week. Gas has been checked and it was no contamination in it. The spark plug is brand new and correctly gaped. And it is dry.

 

[Baylinerchuck]

I hate to be the one to ask, but you did have it hooked to a hose to test run it right? :behindsofa:

Basic troubleshooting, does it have spark, does it have fuel. You did just rebuild the carb, it might be a good idea to start there. Was the carb nasty? White powder deposits? If so, you might want to check the fuel pump, filter, and tank/ anti siphon valve.

 

[Dax68]

I hate to be the one to ask, but you did have it hooked to a hose to test run it right? :behindsofa:

Basic troubleshooting, does it have spark, does it have fuel. You did just rebuild the carb, it might be a good idea to start there. Was the carb nasty? White powder deposits? If so, you might want to check the fuel pump, filter, and tank/ anti siphon valve.

Yes, Had hose running all during test. Does have spark on all eight plugs. Carb was not as nasty as i was expecting just normal discoloration. No white power deposits. Fuel pump is working fine and filters were just changed.

At this point i see it is a fuel related issue and not an electrical issue so thinking about ordering refurbished carb from ebay which is around $350.00 i don't know that would resolve the issue though.

 

[Searay205]

when you try to start hot and it won't hold the throttle wide open and crank. Almost sounds like vapor lock. Feel free to squirt some ether in the carb. You may need a insulator gasket between manifold and carb if its vapor locking.