883600T04 Mariner POWERHEAD ASSEMBLY

start by: a) remove fuel injection lines1. Remove the cover from the front of the timing gear cover.2. Loosen the bolt that holds the fuel injection pump drive gear to the fuel injection pump camshaft. Hit the bolt with a hammer to loosen the gear from the camshaft. Remove the bolt and washer. If the fuel injection pump drive gear does not loosen from the camshaft, remove the bolt and washer. Install tooling (A) on the gear and loosen the gear from the camshaft. 3. Remove fuel supply line (1) and fuel return line (2). Remove bleed line (3). Disconnect fuel pressure line (5).4. Disconnect governor linkage (4) and the bracket from the governor and pump housing.5. Remove the bolt that holds the drain line for the fuel transfer pump to the engine. 6. Remove the nuts that hold the fuel injection pump housing and governor to the timing gear plate and remove fuel injection pump housing and governor (6).Install Fuel Injection Pump Housing And Governor
1. Put the No. 1 piston at the top center compression position before installing the fuel injection pump housing and governor on the engine with the following procedure. a) Remove plug (1) from the flywheel housing. Turn the crankshaft clockwise (as seen from the front of the engine) until a 3/8"-16 NC bolt 2 1/2 in. long can be installed through the timing hole in the flywheel housing and into the hole in the flywheel. Never turn the crankshaft backward to install the bolt in the flywheel.b) Disconnect the breather from the valve cover. The rocker arms for No. 1 piston can be seen through the breather hole in the valve cover.c) Check to see if both rocker arms for the No. 1 piston can be moved backward and forward by hand through the breather hole. The No. 1 piston is at the top center compression position when the bolt is installed in the flywheel, and both rocker arms for No. 1 piston can be moved backward and forward.d) If both rocker arms can not be moved, the No. 1 piston is not at the top center compression position. Remove the bolt from the flywheel. Turn the crankshaft clockwise (as seen from the front of the engine) one full turn (360°) and install the bolt again. 2. Remove timing pin (2) from cover (3). Remove the bolt from the cover and install the timing pin in the groove (slot) in the fuel injection pump camshaft.3. Inspect the O-ring seal for the fuel transfer pump. Install a new seal if needed. Put clean engine oil on seal. Put the fuel injection pump housing and governor in position on the engine. Install the nuts that hold it in place. 4. Install the washer and bolt (4) that hold the pump drive gear to the camshaft. Tighten the bolt to a torque of 110 5 lb.ft. (15.2 0.7 mkg).5. Check the timing to make sure it is correct: a) Remove the timing pin from the pump camshaft and the bolt from the flywheel.b) Turn the crankshaft clockwise (as seen from the front of the engine) approximately 1/2 turn. Install the timing pin again.c) While turning the crankshaft clockwise (as seen from the front of the engine) push on the timing pin until it slides into the groove (slot) in the pump camshaft.d) Install the bolt in the flywheel. The timing is correct when the bolt is installed in the flywheel and the timing pin is installed in the groove (slot) in the pump camshaft.e) Remove the timing pin and the bolt. Install the plug in the flywheel housing. Install the bolt in the cover on the pump housing. 6. Install cover (5). Install fuel bleed line, fuel return line, and fuel supply line. Connect fuel pressure line.7. Connect linkage to governor. Install bolt for transfer pump drain line.end by: a) install fuel injection linesb) adjustment of high and low idle (see GOVERNOR ADJUSTMENTS in TESTING AND ADJUSTING)Separation Of Governor From Fuel Injection Pump Housing
start by: a) remove fuel injection pump housing and governor1. Put the fuel injection pump housing and governor in position on tool (A).2. Remove the bolts that hold the governor housing to the fuel injection pump housing. 3. Remove governor housing (2) from the fuel injection pump housing.4. Remove cover (1) over the stop bar. 5. Remove spring (5), (wave) washer (4), and guide (3) from the governor housing. 6. Remove the nut and bolt that holds stop bar (6) to the fuel injection pump housing. Remove the stop bar. 7. Remove seat (7) and over fueling spring (8). 8. Push in on lever (10) and remove pin (9) from the fuel injection pump housing.9. Remove the ring that holds lever (10) to the dowel and remove the lever. 10. Remove riser (follower) (13) from the shaft.11. Pull up on shaft (11) and remove the shaft and lever (12) from the fuel injection pump housing. Shaft (11) has an O-ring seal on it which can make it difficult to remove the shaft from the fuel injection pump housing. 12. Remove cover (14) for the flyweights with tool (B). Tool (B) can cause damage to the cover. Always inspect the cover and install a new cover if needed.13. Install the timing pin in the groove (slot) in the fuel injection pump camshaft to keep the camshaft from turning. 14. Remove the bolts that hold flyweight assembly (15) to the camshaft and remove the flyweight assembly from the fuel injection pump housing.15. Remove the timing pin from the fuel injection pump housing.Connection Of Governor To Fuel Injection Pump Housing
1. Put the fuel injection pump housing in position on tool (A). 2. Install timing pin (1) in the groove (slot) in the injection pump camshaft to keep the camshaft from turning.
Make sure the pin that holds the shaft for the flyweights is in correct position on the back of the flyweight assembly.
3. Put the flyweight assembly in position on the camshaft and install new