Re: New noise after engine removal and reinstallaion
i guess the memory is the first thing to go--i went back and looked at the manuals. my merc manual (#2) says,
"Place drive coupling on studs and install washers and lock nuts. Torque nuts to specifications with Torque Wrench and Adapter." so that's as i remembered. as far as the flywheel, all it says is to line up the dowel hole. merc manual #3A says to check the flywheel runout with a dial indicator--but that's in the axial (fore-aft) direction, not the radial direction. sorry for the confusion--in my case, i guess it couldn't be helped...
it does strike me as odd to go through the alignment procedure so carefully before mounting the sterndrive, but the coupler just bolts on. i wonder what the tolerances are for volvo and for merc. with the merc alignment tool and the grease method (use the spline marks in the grease to judge alignment), i'd guess the shaft/coupler radial alignment is to about .025" or so (?). i wonder if the coupler/flywheel/mount holes are that close when in good shape. they must be, because everyone agrees that not getting the alignment right leads to coupler failure. i'll pay closer attention when i mount my new coupler.
kahlua, you mentioned the starter bendix not releasing--i recently had that. that is a racket--sort of faster and higher pitched than some of the clunk noises the drive can make. i was going to guess u-joints, but on a friend's boat with u-joints going, the knocking was lower pitched. maybe they can make other noises, too. sorry i can't help more, hope you find the problem.