1984 StarCraft with a 2.5 liter I/O engine (model 252STHRCRA)

[snowaczyk]

I think i have a bad expansion plug on the rear of the engine. Can anyone tell me what is involved in pulling or separating the engine in order to replace the plug? I would also like to find a repair manual for this project.

 

[Don S]

Re: 1984 StarCraft with a 2.5 liter I/O engine (model 252STHRCRA)

Since that model # if for an OMC motor, I'm going to move this to the OMC forum.

 

[Howard Sterndrive]

Re: 1984 StarCraft with a 2.5 liter I/O engine (model 252STHRCRA)

depends on the hull.... some undo all the bellhousing bolts and pull the engine only. some remove the outdrive, then remove the boot, and lift the whole engine and intermediate housing out together
I have always done the latter.

ebay best place for a factory omc manual - the aftermarket manuals are not as good

 

[snowaczyk]

Re: 1984 StarCraft with a 2.5 liter I/O engine (model 252STHRCRA)

If I just undo the bell housing bolts and pull the engine, what about putting it back together when I am done? Will I have to get an aligning tool and ???. How would you suggest to do it and if you can be detailed??

 

[Howard Sterndrive]

Re: 1984 StarCraft with a 2.5 liter I/O engine (model 252STHRCRA)

no alignment tool for your setup. The dowels on the bellhousing line it up. I can't be too detailed, because I have never worked on your boat - I don't know what I can get to and what I can't hanging upside down in the bilge.
However, I always pull the intermediate with the engine - gives me a chance to check how solid the lag screws are into the stringers at all 4 mounts.
The OMC manual will show you how to remove the shift cable, and then the sterndrive. You need to be careful to take the battery right out of the boat and treat that cable with respect (it is expensive) Then you can remove the big boot on the rear of the transom. Unhook electrical at the big round harness plugs, undo all the lag screws and lift.

 

[snowaczyk]

Re: 1984 StarCraft with a 2.5 liter I/O engine (model 252STHRCRA)

Thanks. It is a little 4-cyl. I do have some room to work around but it is tight. From what you said I take it that I should remove everything to do the job right. I will need to get that manual.

 

[snowaczyk]

Re: 1984 StarCraft with a 2.5 liter I/O engine (model 252STHRCRA)

Regarding the manual, are you saying the Deloc Marine manual is a good one to get?

 

[Howard Sterndrive]

Re: 1984 StarCraft with a 2.5 liter I/O engine (model 252STHRCRA)

OMC factory manual is the one to get. Seloc is "ok", Clymer is good for lining the bird cage.

 

[snowaczyk]

Re: 1984 StarCraft with a 2.5 liter I/O engine (model 252STHRCRA)

Trying to pull that 2.5. Do I have to take the fly wheel off before I can separate the engine from the bell housing? I've undone all the bolts and electrical and tried to move the engine 6 inches forward like seloc manual says but I can only move the engine about 1 in separation from the bell housing. Any thoughts??
Steve

 

[Bondo]

Re: 1984 StarCraft with a 2.5 liter I/O engine (model 252STHRCRA)

Trying to pull that 2.5. Do I have to take the fly wheel off before I can separate the engine from the bell housing? I've undone all the bolts and electrical and tried to move the engine 6 inches forward like seloc manual says but I can only move the engine about 1 in separation from the bell housing. Any thoughts??
Steve

Ayuh,... My guess is, the splines on the drive are hung on the flexplate, from a lack of grease...

Rock the crankshaft back, 'n forth to see if it'll free up...

 

[snowaczyk]

Re: 1984 StarCraft with a 2.5 liter I/O engine (model 252STHRCRA)

I've tried to use a pry bar, to rock the engine and so forth. I don't know if I have to unbolt the fly wheel tho

 

[Howard Sterndrive]

Re: 1984 StarCraft with a 2.5 liter I/O engine (model 252STHRCRA)

I can't imagine how you are going to unbolt the flywheel unless your arms are as thin as popsicle sticks. But if you feel you can get those bolts out, that will work. I can't see it happening.

What I would probably try to do, is remove the outdrive, then unbolt the intermediate shaft seal retainer at the rear of the intermediate and try a couple of heel bars to pull the intermediate shaft rearward out of the engine coupler. or maybe rig a slide hammer up to the intermediate ball gear once the bolts are out of the retainer... that should shock it free of the coupler.


Some folks have reported having to remove the engine and intermediate and flip the whole mess upside down on the shop floor to get a torch in and heat those splines. I tend to think that's unnecessary if the int shaft can be pulled back. Be careful prying on the bellhousing - it's cast aluminum.... brittle.. and prying there isn't going to help much anyways

 

[snowaczyk]

Re: 1984 StarCraft with a 2.5 liter I/O engine (model 252STHRCRA)

Ok I'll try that. I just took the out drive off and the boot in preparation to pull the whole unit and work from there. I will try the ball gear and get back to ya. Thanks again. Boy did i have a heck of a time with the shift cable

 

[snowaczyk]

Re: 1984 StarCraft with a 2.5 liter I/O engine (model 252STHRCRA)

ya, that's not going to work because I cannot get to all four bolts because that gear is in the wrong position and i can't get it to turn. Any other ideas? I do have the boot off. can I disco the unit from the back of the bell housing and would that do any good?

 

[snowaczyk]

Re: 1984 StarCraft with a 2.5 liter I/O engine (model 252STHRCRA)

Thanks Commander you really know you stuff. I went back at it and removed the four bolts and a little persuasion and the shaft came free and then the engine came out. Just like I suspected it had an expansion plug blown right out and setting in the bottom of the bell housing. The first mechanic was right and the second one said it had a cracked block and I needed a whole new short block was wrong. Any thoughts as to what I should now replace since I have the whole thing apart pretty much? Just as preventive maintenance at this stage?

 

[snowaczyk]

Re: 1984 StarCraft with a 2.5 liter I/O engine (model 252STHRCRA)

Any ideas where to buy parts for this boat engine that will not cost an arm and a leg??

 

[Bondo]

Re: 1984 StarCraft with a 2.5 liter I/O engine (model 252STHRCRA)

and the second one said it had a cracked block and I needed a whole new short block was wrong.

Ayuh,... Yer alittle premature with that statement, til ya replace the coreplug, 'n Test it....

It could Still have a Cracked block....