camshaft and balance shaft installation

[dlogvine]

I am rebuilding 2002 Mercruiser 4.3 v6. I started with freeze plugs a while ago and was waiting for the rebuild kit. Got it a couple days ago and started with camshaft bearings and a balanced shaft bearing. I think I forgot to insert a couple freeze plugs that are supposed to cover camshaft and balanced shaft bores in the back. Since I took the engine apart a long time ago im not sure if both bores are supposed to be plugged (Im almost 100% sure they should be). However i wonder if I can install the freeze plugs with the camshaft and balanced shaft already installed. This is the first question. The second is, what holds the camshaft from sliding back? There is a retaining plate on the front and driving and then timing gear, but neither would prevent the motion of the camshaft back. The other question, in the manuals installation of the driving gear on the balanced shaft states only one thing, not to hit the gear, since it might push the rear freeze plug out. So the third question is how to install the driving gear on the balanced shaft.
I feel kind of dumb since I already rebuild this type of engines a couple times, however they were older ones without the balanced shaft.
Thank you, will post the pictures in a little while.

 

[dlogvine]

[No message]

 

[achris]

Yes you need both plugs in the back. That's how they stop the oil leaking out at that point...

The balance shaft driven gear is attached by screws, not hitting...

Chris......

 

[dlogvine]

Last question, what stops the camshaft from sliding towards the rear and either hitting the rear freeze plug or getting the driving gear run on the block? From what I can see the thrust plate is just blocking it from sliding forward

 

[Scott Danforth]

thrust plate and timing gear does most of it, however the core plug (they are not freeze plugs) keeps it from flying out the back of the motor until you get the thrust plate installed.

use permatex #1 on the core plugs

 

[dlogvine]

Thank you Scott, so the camshaft does not rub on the core plug?

 

[achris]

Thank you Scott, so the camshaft does not rub on the core plug?

Nope....

Until you put the gear on, yes the camshaft can slide all the way back. Once the gear is on, it can't... The inside of the gear IS the thrust surface...

Chris.........

 

[dlogvine]

Worked for several hours on this engine today and installed the camshaft, balanced shaft, crankshaft. Had to pull the engine of the stand to install the core plugs on the camshaft and balanced shaft. After consulting with machine shop mechanic installed drive gear on the balanced shaft (was afraid to damage it before) and then the timing set. Finished the day with installation of the pistons. The only question ive got is how can i turn the crankshaft, when all the rod cap nuts are tightened up to the right torque, i believe 20 ft lbs. On my older 4.3 v6 the crankshaft had appropriate hiles for a breaker bar or extension bar, so i was able to turn the crankshaft. This engine has a different crankshaft, so i no longer can manually turn it. Is there any other way to turn the crankshaft without the starter?

 

[Bt Doctur]

install the harmonic balancer, and either install a steering wheel or 3 fine thread bolts , rotate with piece of pipe

 

[Bt Doctur]

mains are 75Ft/Lbs and rods are 45Ft/Lbs. Sounds like you need a manual and not be guessing at the critical items

 

[dlogvine]

mains are 75Ft/Lbs and rods are 45Ft/Lbs. Sounds like you need a manual and not be guessing at the critical items

Incorrect, 45 ft lbs is for the old engines, till 97, newer ones require 20 ft lbs torque. And I do have a manual

 

[Bt Doctur]

Better read it again then to the part where it says 20Ft/Lbs FIRST PASS , then +70 Degrees angle torque

 

[Bt Doctur]

http://162.144.28.33/lib/mercruiser/manuals/mercruiser32.html#/66

 

[Scott Danforth]

use a crank shaft socket.

Bt Doc has you covered on the rod torque.

 

[Bt Doctur]

Sure hope he got the head bolts right too