Sorry for the brutally long post...but I just need a quick sanity check on a new longblock install. Basically, if any of you spot anything I am missing, or am doing out of order, please let me know (I have done a lot of small work on engines, but never a full install, so even let me know the small stuff if you can...also, if there is any "watch out for this" type stuff). I have the Clymer manual for my model.<br /><br />The engine/OD/boat specs : 3.0L GM with DDIS ignition ; AlphaOne OD ; Maxum SC200 1989 ; Never been in salt water<br /><br />Prior to all of this, the boat/engine/outdrive ran excellent. The old engine had a water jacket crack from poor winterizing (costly lesson #1), then over the winter some crud blocked the bilge drain, and during our monsoon-like spring, the inside of the boat flooded (hard work lesson #2). The water level got about 2/3 of the way up the engine (and in the cabin of the boat, but I got that all cleaned up...didn't get as high as any of the seat cushions fortunately). It never got near the shift or throttle cables, or the wiring harnesses. Just a few of the ends of the wires that were attached to stuff (starter, etc.). Here is what I have done/plan to do.<br /><br />1: Drain the boat (done)<br />2: Disconnect everything electrical, remove batteries (done)<br />3: Place the shift lever in forward; remove stern drive (done)<br />4: Disconnect everything attached to the engine, and remove engine (done)<br />5: Completely clean the bilge area and the entire cabin (done)<br />6: Purchase a new 3.0L longblock with HEI ignition installed and retro-fit 12-3/4 flywheel (done)<br />7: Purchase the following new components : Starter, alternator, drive belt, all engine gaskets, slave solenoid, 50amp circuit breaker, thermostat, all hoses, sterndrive gasket kit, carb rebuild kit (done).<br />8: Removed from old block and completely cleaned (pressure wash/degrease where appropriate/compressed air blowout and thoroughly dry...etc) the following parts : Manifold, riser and boot (?) connectors, alternator brackets, coupler (fully inspected...looks like new!), flywheel housing, thermostat housing and cover, temp send fitting, oil pressure send fitting, block drain, valve cover with shift assist switch, fuel pump. (done)<br />9: Installed all of the above parts (new and cleaned) with new gaskets (done)<br />10: Rebuild carburetor (mercarb 2nd version), and reinstall (to do) <br />11: Wire all on-motor components (to do)<br />12: Inspect/Replace (if necessary) bilge pump and blower (to do)<br /><br />12a: (per Trent's suggestion) Inspect & grease gimbal bearing, all fittings, u-joints, and driveshaft. Remove prop and grease propshaft, reinstall prop (to do)<br /><br />12b: (per achris60's suggestion) Inspect/clean/replace shift cable. Pull & grease exhaust tube bolts & transom plate nuts (to do)<br /><br />13: Mount the new engine (to do)<br />14: Align the engine (to do)<br /><br />14a: (per outboardguy's suggestion) Replace driveline yoke seal (to do)<br /><br />15: Remount the stern drive with new gaskets and o-rings (to do)<br />16: Drain and refill the stern drive lubricant (to do)<br />17: Drain and refill fuel tank (to do)<br />18: Fill new engine with oil (to do)<br />19: Reconnect electrical harness, all wires, fuel lines, and throttle and shift connections (to do)<br />20: Replace and install new batteries (to do)<br /><br />---here is where I get a little sketchy---<br /><br />21: Place the muffs on, and start it up?<br />22: Check/adjust the engine timing? (I will hunt the forum for procedures)<br />23: Warm it up, and fully inspect all hoses, belts, gaskets, etc?<br />24: Check all gauges, proper function of shifting, tilt/trim/etc?<br />25: Lake test it? (following engine break in procedures)<br />26: If everything is OK, break in the engine properly?<br /><br />---ok...now I know the parts to do after it is running well---<br /><br />27: Sit back and enjoy a cold one, because I saved myself a few grand by doing it myself (hopefully)<br />28: Enjoy a renewed boat<br />29: When the season is done, WINTERIZE IT PROPERLY!<br /><br />Thanks in advance for you help.
