Mercruiser 5.7 flywheel removal

[SPDauto]

Hello folks, I am new to the forum, although have been a long time reader.

I have a 1980's 23ft Sunseeker with a Penta KAD conversion and have recently bought a 21ft Mariah z202 with a 5.7 Mercruiser.

The Mariah came to me very cheap partly due to the fact that the starter stuck and apparently stripped a few teeth off the flywheel.

I was wondering, is it possible to remove the flywheel to replace the ring gear with the engine in situ? I know the drive will need removed but would like to avoid complete engine removal if possible.

Any help would be great!

Thanks

 

[sogood]

It would probably depend on how much room you have. It may be do-able but pulling the engine isn't such a big deal. And you'll have access to lots of things that are a PITA to get to and so, are often neglected. Also, I think there are different ring gears with different numbers of teeth on them. Worth looking into.

 

[SPDauto]

I have very little room, can really only get to the front half of the engine easily. Its more the height needed to lift it out completely I was trying to avoid, but if that's how it has to be I can organise something im sure. Il not order anything until I have the flywheel off and can count the teeth.

Unsure how to upload pictures on this forum, do they need hosted elsewhere?

 

[Beamishken]

Theres no way to get the flywheel off without moving the engine. The belhousing forms the rear engine mounts. You might be able to support the rear and wiggle the engine forward and work under it to undo the bolts and remove bellhousing and coupler then flywheel. In reality it will be quicker and easier to pull the engine out and work on a bench or the floor. The engines are installed in such a manner that they are easy to remove. 2-3 hours will see the engine out

 

[SPDauto]

that's what I was needing to know, especially as im sure the flywheel bolts will be well torqued up. Not ideal in a small space. Il try and post a picture of the room I have to work. Im pretty sure im going to have to strip quite a bit off the engine before it will come out the hatch.

 

[SPDauto]

 

[Andy Cox]

Theres no way to get the flywheel off without moving the engine. The belhousing forms the rear engine mounts. You might be able to support the rear and wiggle the engine forward and work under it to undo the bolts and remove bellhousing and coupler then flywheel. In reality it will be quicker and easier to pull the engine out and work on a bench or the floor. The engines are installed in such a manner that they are easy to remove. 2-3 hours will see the engine out

+1 on above. There is no way to do it, as said before, the rear mounts are incorporated into the bell housing which needs to come off in order to access the flywheel. You may have to remove pieces of boat and trim panels etc, but it's a fairly easy job to pull it right out.

 

[QBhoy]

I’m afraid not.

 

[Andy Cox]

OK, looking at the photo it looks as though the boat was built around the engine, which is not that uncommon.

Worst case scenario will be to have someone cut an access panel in that moulding above the engine to give you the room you need. It can then either be glassed back in properly after you've put the engine back in or find a way of making the panel semi permanent but so it can be removed by removing some screws etc.
Andy

 

[Beamishken]

Its very unlikely you will need to start cutting anything to get the engine out. They often hide fasteners behind trim etc but very unlikely on a boat like that that they assembled the hull and deck after engine installation. There is likely a way to unbolt the upper cowl somehow

 

[Andy Cox]

Its very unlikely you will need to start cutting anything to get the engine out. They often hide fasteners behind trim etc but very unlikely on a boat like that that they assembled the hull and deck after engine installation. There is likely a way to unbolt the upper cowl somehow

I agree that would be the preferred option and it may the photograph is confusing the issue, but it doesn't look as though it unbolts. But as said, it' hard to say from the photo's. It should be fairly obvious though if that section is easily removable.

 

[SPDauto]

takes days for my posts to be approved so apologies for the delay in replies.

unfortunately there is no way to separate the ‘cowling’ in the photo. Its all one piece, what you see in the photo is part of the entire top of the boat.

Iv managed to get a good look at it over the weekend and i think there is a chance it might come out with the carb and manifolds removed. Its going to be a bit of a juggle though. Id be keen to avoid having to cut anything obviously. Will keep this updated with how i get on!

Many thanks for the help folks

 

[simonfraser]

i'd think about removing the cowling in some way.
re-post it on the forum under a different heading with more pics and peeps will come up with all sort of suggestions.
that way you gain better access for future issues too.

 

[SPDauto]

I could cut the cowling away right enough! As its covered with a carpet box, the sun pad and the back bench anyway! Never thought of that, would give me slightly more room to work with

 

[simonfraser]

cut some of it away under the sun pad too ?

 

[SPDauto]

That is under the sun pad, back edge of the sun pad is pretty much that cowling in the pic. Its hinged and when its down it covers the engine. The lip removed and the carb off would probably be enough to get it out. Just wish it was straight up lift as il more than likely have to use a tractor or something with forks to remove :/

 

[simonfraser]

extend the sun pad and make the hole bigger ?

 

[Beamishken]

That is under the sun pad, back edge of the sun pad is pretty much that cowling in the pic. Its hinged and when its down it covers the engine. The lip removed and the carb off would probably be enough to get it out. Just wish it was straight up lift as il more than likely have to use a tractor or something with forks to remove :/

I'd be very reluctant to cut anything even if it does involve removing ancillary items from the engine. On this type of boat there is usually a way without cutting, ask yourself would the builders build a boat they couldnt repair under warranty without cutting it up? Pretty unlikely imho.
Re lifting the engine I've used a variety of machines ,diggers tractors etc for lifting engines and all can be a bit clunky when needing to manoeuvre out of small spaces. What i do is add a pull lift into the rigging so I can fine tune the lift without using the machine's hydraulics which gives fine control in a tight spot to avoid any damage

 

[SPDauto]

I am reluctant to cut anything. That's a good idea, use a fork or the likes to attach a pulley block to or similar to make it a bit smoother! thanks for that!