Tips on Engine Removal - '92 Searay 4.3 Mercruiser?

Discussion in 'Gas Engines/Drives/Transmissions/Props' started by zghorner, May 11, 2022.

  1. zghorner

    zghorner New Member

    May 11, 2022
    '92 searay 200 Overnighter
    4.3 mercruiser
    My dad bought a '92 overnighter that wasn't winterized and has a bad block (he pulled the heads and verified it is trash)...He has been an Auto mechanic his entire life so no worries on anything basic or similar to cars/trucks...but he isn't quite sure about what is required to remove the engine from this boat.

    his primary question is whether or not the drive has to be removed from the boat or can the engine simply be unbolted in the back and taken out? I have a large skid steer so maneuvering it around is not problem.

    also, any specialty tool required for the job?

    Any other useful tips/tricks for this process? He is searching for the correct long block now and i believe they want the damaged block for core charge so it will be coming out soon.

    PS: He is probably going with Jasper engines as he has had good luck with them in the past with his shop and trusts their warranty.
    Last edited: May 11, 2022
  2. scoflaw

    scoflaw Well-Known Member

    Aug 10, 2011
    cape cod mass, cape coral fl
    1999 Powerquest legend 260 sx 502 mag
    2005 Baja 242 islander 496
    502 mpi Bravo 1
    496 mag B1
    Drive has to come off. I suggest taking the transom assembly off and reseal it, you don't want to do this twice.
    zghorner likes this.
  3. zghorner

    zghorner New Member

    May 11, 2022
    '92 searay 200 Overnighter
    4.3 mercruiser
    total bummer. thank you for the reply.
  4. Bill Curtis

    Bill Curtis Well-Known Member

    Mar 24, 2022
    Ahoskie, NC
    '95 220 Overnighter
    454 Mag Bravo3
    Also, while engine is out, check the rear motor mounts on the transom plate and check exhaust pipe to the transom plate for excessive corrosion. Then you have your bilges and bilge pump while engine is out, too. Check the steering hinge pin if you remove the transom plate, too. Easy to change when all apart already. Almost impossible when assembled.

    And don't forget to disconnect fuel line, control cables, water hoses, Power Steering / hoses (if you have PS), any oil cooler water hoses (if you have oil coolers) and the battery cables to starter. Be careful and document where the "bonding wires" are and don't break one that got missed when pulling engine. Electrical harness just unplugs.

    Take lots of pictures and get the engine alignment / bearing / bellows tools for re-assy.
    Nater Potater and zghorner like this.
  5. Southern Pirate

    Southern Pirate Member

    Nov 17, 2019
    2005 sea ray 270 amberjack
    5.7 Mercruiser w/Bravo III Drive
    I just removed the motor in my boat. No special tools required to remove. Just make sure to label the wires and like advised above, take pictures. When you replace the motor, you will need an alignment rod to check for proper alignment. Once you have it aligned, put the out-drive back on and you are set.
    zghorner likes this.
  6. Nater Potater

    Nater Potater Well-Known Member GOLD Sponsor

    Oct 19, 2020
    Southwest Idaho
    1992 300DA Sundancer
    Twin Merc Alpha I Gen II I/O's with 5.7 V8's
    Another item to check while it's out is the coupler. It's what bolts to the crankshaft that the outdrive splined shaft slides into. It looks like a giant rubber shock bushing and will leave you dead in the water if the splines go away. Since you have to pull the outdrive anyway, you can hand-fit the coupler (once it's out) to the outdrive's shaft and check for any obvious play. For all the work involved in replacing this piece, now's the time to ensure it's serviceable. Depending on the style (I think there's only two for that time period) It'll look like this:

    or this:
    zghorner likes this.
  7. mrsrobinson

    mrsrobinson Well-Known Member SILVER Sponsor

    Mar 9, 2006
    Virginia, USA
    2001 Sea Ray 380DA
    3126 purring CATs
    They "aligned" the engines on the 330DA when they were reinstalled. Never quite knew how they did it though.
  8. Pirate Lady

    Pirate Lady Well-Known Member

    Jun 2, 2020
    Chesapeake Bay, Middle River
    Sundancer 250 ‘91
    7.4 Bravo 1
    To add to what Potato Man said…
    Last year while getting some work done the mechanic told me my coupler may need to be replaced down the road. These are experienced boat guys and said 2.5 hours to remove, same in. About $500 total labor. He said no big deal. Your dad will probably be good doing the work but he may want a boat guy along to show the tricks.
    Nater Potater likes this.
  9. Bill Curtis

    Bill Curtis Well-Known Member

    Mar 24, 2022
    Ahoskie, NC
    '95 220 Overnighter
    454 Mag Bravo3
    Youtube is your friend on this one. Not hard to do (best with 2 people), but access to front engine mounts can be difficult, at best, on some boats
  10. atrick

    atrick Active Member PLATINUM Sponsor

    Mar 4, 2017
    1995 searay 290 Sundancer
    1990 21 maxum
    Twin 4.3 mercrusers with alpha one genII drives
    305 chevy with a alpha one drive
    When I pulled starboard motor out of my 95 290 DA I remover risers and exhaust manifold in boat first then its real easy to see and get to motor mounts, wiring on starter, ground wires on back of motor and any water lines with clamps plus motor is a little nearer which makes it a little easier to get out
    Nater Potater likes this.

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