805612 Mercruiser BOLT

start by:a) remove fuel injection linesb) remove electric starting motor1. Use the following procedure to put the No. 1 piston at top center on the compression stroke. No. 1 piston at top center (TC) on the compression stroke is the starting point for all timing procedures. The engine is seen from the flywheel end when direction of flywheel rotation is given. Do not turn the flywheel backward.a) Remove the plug from the flywheel housing and the breather from the valve cover. b) Turn the flywheel counterclockwise with tooling (C) until a 3/8"-16 NC bolt (1) at least 2.5 in. long can be installed in the flywheel through the hole in the flywheel housing. Do not turn the flywheel backward. 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. The No. 1 piston is at top center on the compression stroke when the bolt can be put in the flywheel through the hole in the flywheel housing, and both rocker arms for the No. 1 piston can be moved backward and forward by hand.d) If both rocker arms can not be moved by hand, the No. 1 piston is not at top center on the compression stroke. Remove the bolt from the flywheel and turn the flywheel counterclockwise one full turn (360°). Install the timing bolt in the flywheel again. Check to see if both rocker arms for the No. 1 piston can be moved backward and forward by hand. 2. Remove the cover on the fuel injection pump housing and install tool (B). If tool (B) can not be installed in the groove in the camshaft, it will be necessary to first loosen the timing gear and then turn the camshaft.3. Put identification on the wires for correct installation and disconnect wires (2) and (3).4. Remove fuel filter (4) from the fuel injection pump housing and governor. 5. Remove nuts (5) and cover (6) from the front cover. 6. Put a mark on governor control linkage (7) at the governor for correct installation.7. Loosen the nut and disconnect governor control linkage (7) from the governor.8. Remove the bolts and bracket (9) from the governor.9. Remove the bolt and disconnect wire harness clip (8) from the engine.10. Remove tube assembly (10) from the engine. 11. Disconnect tube assemblies (11) and (13), the fuel ratio control and fuel pump housing.12. Remove the bolt and disconnect wire harness (12) from the engine.13. Loosen bolt that holds the timing gear to the full injection pump camshaft about 3.2 mm (.125 in.). 14. Install tooling (A) and loosen the timing gear on the camshaft.15. Remove tooling (A), bolt and washer. 16. Remove two bolts (16) and three nuts (14) that hold the fuel pump housing in place.17. Use two persons to remove fuel pump housing (15) from the engine. The weight of the fuel pump housing is 27 kg (60 lb.).Install Fuel Injection Pump Housing And Governor
1. Be sure the O-ring seals are in position on the fuel injection pump housing and governor and put clean oil on the O-ring seals.2. Install tool (A) in the fuel injection pump housing. Turn the camshaft until the tool (A) goes in the groove in the camshaft. 3. Put fuel injection pump housing and governor (1) in position on the timing gear plate and the oil manifold. Install the three nuts that hold the fuel injection pump housing to the timing gear plate and the two bolts that hold the governor housing to the oil manifold.
After the fuel injection pump housing and governor are installed on the timing gear plate, be sure the rack is free to move. The O-ring seal on the drive end of the fuel injection pump can hold the rack and prevent free movement of the rack. If the rack does not move freely, remove the fuel injection pump housing and governor and check the O-ring seal on the drive end of the fuel injection pump housing.
4. Connect tube assemblies (2) to the fuel injection pump housing and governor. 5. Connect wires (3) to the fuel shutoff solenoid and wires (4) to the sending unit. 6. Install tube assemblies (5) to the fuel injection pump housing and governor. 7. Connect governor control linkage (6) on the governor.8. Install bracket (7) on the governor. 9. Install tool (B) on the timing gear. Use torque wrench (8) and put a torque of 68 N m (50 lb.ft.) on the timing gear to remove the gear clearance (backlash). Use torque wrench (9) to tighten the bolt on the pump drive to a torque of 270 25 N m (199 18 lb.ft.). 10. Install fuel filter (10) on the fuel injection pump housing. 11. Connect wire harnesses (11) and (13) on the engine with the clips.12. Install the gasket and cover (12) to the front cover. 13. Remove tool (A) and install the gasket and cover (14) on the fuel injection pump housing and governor.end by:a) install fuel injection linesb) install electric starting motor