Merc 420 Cyclone engines

[old377guy]

Glad to see the old girl getting some love. Keep us posted Brian.

[BDC1013]

Didn't get any progress on the engine yet, work wanted the engine work to be done at my house so yesterday i moved the engine home. Plan to to tear down to just heads and intake. The mechanic told me to open every hole on the engine and WD-40 the heck out of it to see if I can get the engine to fully rotate without any problems. He said then he'd do a leakdown and we'd go from there.

here is some more eye candy.

[BDC1013]

I noticed that the boat was not as friendly being towed without the engine in. I think the tongue weight increased dramatically and the truck's suspension couldn't handle the extra weight. Pulling it felt lighter, the down the road the boat was bouncing the truck all over.

[MOBILEMERCMAN]

Towing a boat without engines sucks. Oh well. It is progress. Get on line and look up Spray Nine Grez Off. Get a gallon or two. It is the BEST degreaser on earth. Use it to clean bilge and parts for paint.

Also go to a hydraulic hose shop and purchase some plugs for fuel lines.

Keep up the good work.

[BDC1013]

Thank you Sir, was just going to ask about cleaning it. I'll check that stuff out but a good power wash should get it looking brand new. I tore most of the accessories off the engine tonight and got hung up on one allen bolt that holds the exhaust manifold on. Going to have to go to the tool store tomorrow to get an allen socket set, and something to get those crazy hex heads off the intake. Anyone have an idea what those are called and what size they are?

[BDC1013]

[Ratickle]

I can't tell from the picture, but I'm assuming that it's maybe been converted to E-Torx bolts? Sometimes called Star Head bolts? If so, they usually come in e-6, e-7, e-8, etc, etc.

Do they look like this?

[MOBILEMERCMAN]

They are more likely 12 point 3/8 bolts.

[old377guy]

Brian, I've always removed that type with a plain 12 point socket. Really good to see the progress. If I come down, I'll call and swing by for a look.

[BDC1013]

They are 12 point 3/8 but the angle in which they are into the intake there is no way to get the socket on it. My closed end wrenches are too thick to get on it as well. I went And got a 1/2 breaker bar to spin the engine over and I also got some allen sockets for the Gil exhaust manifolds. Still trying to figure out the four bolts that are against the plenum of the intake. Didn't work on it today... Had to fix a friends car in a parking lot before work.

[BDC1013]

[Ratickle]

Do you have a small swivel to go in the socket to try?

[MOBILEMERCMAN]

The best thing to do is grind a long box end wrench to fit. It was only torqued to 35 lbs and should come out without much effort.

[MOBILEMERCMAN]

The long bolts on the gils might appreciate some heat in the manifold. PB blaster, map gas and patience.

[BDC1013]

Using PB blaster already. Can't get two allen bolts out of the port side manifold. What is this map gas you speak of? Sounds fun.

I'm going to need a 12 point 1/4 drive 3/8 or a special wrench for those intake bolts.

I think I just need a bigger impact gun for the manifold, the 1/2 drive makita is at work and I've been using my 1/4 impact. It's done all but two! I'll bring it home tonight and git er done.

[BDC1013]

I was thinking, spray a little WD-40 down the manifold and hit it with a propane torch. Should be fun

[Ratickle]

Ahhhhh!!!!

He must have been in a hurry, he's talking about MAPP Gas to heat the area, guessing you don't have a set of torches.


Here's a link to a kit.
http://www.totalindustrialsupply.com...SM&Click=80157

[MOBILEMERCMAN]

Mapp gas is available in the little cans like propane but it burns hotter. Usually right next to the propane on the self in a yellow can.

Is it the long bolts on the manifold that are stuck? If so heat the manifold give the PB time to soak in good. If you cant get it out you will need to replace the manifold so Patience. Heat, spray, allow to cool and repeat.

[BDC1013]

I have a propane torch that I might try soon, one problem... I stripped the last bolt head. The very last one to take the manifold off. Should I air hammer the head off? Cutoff wheel? If I get the head of I can weld a nut to the bolt to get it off, or if there is some thread sticking out I can screw I bolt on and lock it with another to try and pull it out. I don't know kinda stuck.

Also still haven't got those bolts off the intake yet. But the engine turns freely with a breaker bar with no weird noises and no hang ups so it's almost time for a leakdown.

[MOBILEMERCMAN]

If you cut the head off you should be able to slid the manifold off.

Air hammer I would not use on anything but, concrete. Lol