ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 016-006   Flywheel Housing

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

WARNING  Support the rear of the engine using the rear support attached to the cylinder head. Failure to support the engine can cause personal injury.

• Disconnect the batteries. Refer to Procedure 013-009 in Section 13.
• If equipped with a wet flywheel housing, drain the oil from the flywheel housing by removing the plug in the bottom of the flywheel housing. Use a container that can hold at least 28 liters [30 qt] of lubricating oil.
• Remove the starting motor. Refer to Procedure 013-020 in Section 13.
• Remove the transmission, clutch, and all related components (if equipped). Refer to the OEM service manual.
• Remove the flywheel/ring gear assembly. Refer to Procedure 016-005 in Section 16.
• Remove the rear engine mounts. Refer to Procedure 016-003 in Section 16.
• Remove any OEM attached components (mufflers, shift mechanisms, air filters, etc.) to the flywheel housing. Refer to the OEM service manual.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

WARNING  The engine lifting equipment must be designed to lift the engine and transmission as an assembly without causing personal injury.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

• Disconnect the batteries. Refer to Procedure 013-009 in Section 13.
• Remove the propeller shaft. Refer to the vessel OEM service manual.
• Remove the marine drive gear, drive gear adapter, if equipped, and the drive plate.
• Use a hoist or suitable lifting device to lift the rear of the engine. Remove the rear engine mounts. Refer to Procedure 016-003 in Section 16.
• Remove the flywheel. Refer to Procedure 016-005 in Section 16.
• Remove the starting motor. Refer to Procedure 013-020 in Section 13.
• Remove the aftercooler mounting capscrews. Refer to Procedure 010-005 in Section 10.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

While supporting the flywheel housing, remove the mounting capscrews.

Use a rubber hammer to loosen the flywheel housing.

Remove the flywheel housing and rectangular seal.

Remove and note the location of any threaded plugs in the flywheel housing.

Remove the access plate and, if equipped, the gasket.

Remove the plug from the barring gear hole.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to avoid personal injury.

WARNING  When using a steam cleaner, wear glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Use steam or solvent to clean the flywheel housing.

Dry with compressed air.

Inspect the flywheel housing for cracks, especially in the bolt pattern area.

Inspect all surfaces for nicks, burrs, or cracks.

Use a fine crocus cloth to remove small nicks and burrs.

Inspect for damaged threads commonly caused by cross threaded capscrews or installing an incorrect capscrew. Heli-coils are available to repair damaged threads.

For wet flywheel housings, apply pipe sealant, Part Number 3375066, to any threaded plugs previously removed.

Install and tighten the plugs. Refer to Procedure 017-007 in Section 17.

Install the access plate and new gasket.

Install the capscrews and tighten.

NOTE: If a gasket was not previously installed, apply sealant, Part Number 3164067, to the perimeter of the access plate.

Install a new o-ring, install the barring gear hole plug.

Install rectangular seal and lubricate with Lubriplate™ 105 multi-purpose lubricant, or equivalent.

Wet Flywheel Applications

Apply a continuous bead of Three-Bond™, or equivalent, around all capscrew holes on the mounting surface of the flywheel housing.

Wet Flywheel Applications

NOTE: The capscrew holes on the mounting pads are drilled through. Coat set screws with Loctite™ 277, or equivalent, and install into holes.

Set Screw Installation Depth (Flywheel Housing)

Inspect the rear face of the cylinder block and flywheel housing mounting surface for cleanliness and nicks or burrs.

Install the flywheel housing over the two ring dowels.

NOTE: Be sure the sealing ring is not damaged during installation.

Tighten the flywheel housing capscrews in the sequence shown.

Install the plastic plug in the tachometer drive access hole.

• Coat the flywheel housing drain plug with pipe sealant and install in the hole in the bottom of the flywheel housing.
• Tighten the plug.
• Refer to Procedure 018-012 in Section V.

Install the access plate and new gasket.

Install the capscrews and tighten.

Install the plug into the barring gear hole.

CAUTION  The dial indicator tip must not enter the capscrew holes or the gauge will be damaged.

Install a dial indicator as illustrated.

NOTE: The extension bar for the indicator must be rigid for an accurate reading. It must not sag. Position the indicator at the 12-o’clock position. Adjust the dial until the needle points to zero.

Slowly rotate the crankshaft. Record the readings at the 3-o’clock, 6-o’clock, and 9-o’clock positions.

NOTE: The crankshaft must be pushed toward the front of the engine to remove the crankshaft end clearance each time a position is measured.

Continue to rotate the crankshaft until the indicator is at the 12-o’clock position. Check the indicator to make sure the needle points to zero. If it does not, the readings will be incorrect.

Determine the Total Indicator Reading (TIR).

The maximum allowable TIR is determined by the diameter of the housing bore. If out of specifications, replace the housing.

Attach a dial indicator gauge, Part Number 3376050, to the crankshaft. The dial indicator can be mounted by any method that holds the extension bar of the indicator rigid so it does not sag. If the bar sags or the indicator slips, the readings obtained will be inaccurate.

Position the indicator in the 6-o’clock position and the gauge at zero.

Slowly rotate the crankshaft. Record the readings obtained at the 9-o’clock, 12-o’clock, and 3-o’clock positions as (a), (b), and (c) in the concentricity work sheet. Recheck 0 at the 6-o’clock position.

The values for (a), (b), and (c) can be positive or negative. See the accompanying figure to determine the correct sign when recording these values.

CAUTION  Do not force the crankshaft beyond the point where the bearing clearance has been removed. Do not pry against the flywheel housing. These actions could cause false bearing clearance readings.

Rotate the crankshaft until the dial indicator is at the 12-o’clock position and 0 the gauge.

Use a pry bar to raise the rear of the crankshaft to its upper limit. Record the value as (d) in the concentricity work sheet. This is the vertical bearing clearance adjustment and will always be positive.

Be careful not to damage the sealing surface when using a pry bar on the crankshaft.

Use the concentricity work sheet to determine the values for the total vertical, and total horizontal values.

The total horizontal is equal to the 9-o’clock reading, (a), minus the 3-o’clock reading, (c).

The total vertical is equal to the 12-o’clock reading, (b), plus the bearing clearance, (d).

Example:

6 o’clock = ref = 0

9 o’clock = [a] = 0.004

12 o’clock = [b] = 0.003

3 o’clock = [c] = -0.002

Using the work sheet and the numbers from the example, the total horizontal value equals 0.006 and the total vertical value equals 0.005.

Mark the total horizontal value on the horizontal side of the chart and the total vertical on the vertical side of the chart.

Use a straight edge to find the intersection point of the total horizontal and total vertical values. The intersection point must fall within the shaded area for the flywheel housing concentricity to be within specification.

Use the total horizontal and total vertical values from the previous example to the intersection point falls within the shaded area. Therefore, the flywheel housing concentricity is within specification.

Use the accompanying chart for SAE 1, 2, and 3 flywheel housings.

If the intersection point falls outside the shaded area, the ring dowels must be removed and the housing repositioned.

NOTE: The ring dowels are not required to maintain concentricity of the housing; the clamping force of the capscrews holds the housing in place.

After the ring dowels are discarded, install the flywheel housing on the engine.

To position the housing, tighten the capscrews enough to hold the flywheel housing in place, but loose enough to enable small movement when struck lightly with a mallet.

Recheck the concentricity. When concentricity is within specification, torque the capscrews to the specified value.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Install both rear engine mounts. Refer to Procedure 016-003 in Section 16.
• Install the flywheel/ring gear assembly. Refer to Procedure 016-005 in Section 16.
• Install the starting motor. Refer to Procedure 013-020 in Section 13.
• Install the clutch, transmission, and all related components (if equipped). See the manufacturer’s service manual.
• Install the transmission and related components (if equipped). Refer to the OEM service manual.
• If equipped with a wet flywheel housing, fill the flywheel housing with oil. Refer to the OEM service manual.
• If previously removed, attach any OEM components (mufflers, shift mechanisms, air filters, etc.) to the flywheel housing. Refer to the OEM service manual.
• Connect the battery. Refer to Procedure 013-009 in Section 13.
• Operate the engine and check for leaks or vibration.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Install the two aftercooler mounting capscrews into the flywheel housing. Refer to Procedure 010-005 in Section 10.
• Install the flywheel. Refer to Procedure 016-005 in Section 16.
• Install the starting motor. Refer to Procedure 013-020 in Section 13.
• Install the drive plate, marine drive adapter, if equipped, and the marine drive gear. Refer to the marine drive gear OEM service manual.
• Install the rear engine mounts. Refer to Procedure 016-003 in Section 16.
• Install the propeller drive. Refer to the vessel OEM service manual.
• Connect the batteries. Refer to Procedure 013-009 in Section 13.
• Operate the engine and check for leaks or vibration.