810844 Mercruiser BOLT

start by:a) remove crankcase guardb) remove hood 1. Tooling (A) can be used to turn the engine to put the No. 1 piston on top center compression. If tooling (A) is used, remove the electric starting motor and install tooling (A) as shown. If tooling (A) is not used, the engine can be turned with the bolt that holds the pulley for the vibration damper.2. Put the No. 1 piston at top center compression as follows: a) Turn the crankshaft clockwise (as seen from the front of the engine) until a 3/8"-16 NC bolt (1) 3 1/2" long can be installed through the timing hole in the flywheel housing and into the hole in the flywheel. Never turn the crankshaft counterclockwise to install the bolt in the flywheel.b) Disconnect the breather from the valve cover. The rocker arms can be seen through the breather hole for No. 1 piston.c) Check to see if both rocker arms 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 the rocker arms for the 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. Remove the bolt from the flywheel. Turn the engine clockwise as seen from the front of the engine one full turn 360° and install the bolt again.3. Turn the fuel supply valve to the "OFF" position.4. Disconnect cable and air line from the air fuel ratio control. Disconnect the air line from the fuel ratio control.
TYPICAL EXAMPLE5. Disconnect rod (5) for the governor control.6. Disconnect fuel lines from the fuel injection pump. Put identification on the lines as to their location on the pump.7. Remove tube (2).8. Remove breather tube (4).9. Disconnect fuel lines (3). Put caps on all openings.10. Remove bolts from bracket (6).11. Fasten a hoist to the fuel injection pump housing and governor. Remove the fuel injection pump housing and governor as a unit. Weight of the unit is 50 lb. (22.6 kg).12. Remove bolts (7) and remove the fuel injection pump housing and governor.Install Fuel Injection Pump Housing And Governor
If the bolt (1) was removed and the flywheel was turned, the engine must be retimed before the fuel injection pump housing and governor are installed.1. Remove the crankcase breather from the valve cover. 2. Remove plug (1) from flywheel housing.3. Turn crankshaft clockwise as seen from the rear of the machine until a 3/8"-16 NC bolt (2) 2 1/2 in. long can be installed in the flywheel through the timing hole. If timing hole is turned too far, turn crankshaft 720°. Do not turn crankshaft back.4. When No. 1 piston is at (TC) top center compression position, the intake and exhaust rocker arms of No. 1 cylinder can be moved through the breather hole in the valve cover.5. If the rocker arm cannot be moved, remove the timing bolt and turn the crankshaft 360°. Install the timing bolt again.6. Install timing fixture plate (B) on the rear face of the accessory drive housing. Install the tool with the dowels in the accessory drive housing in alignment with the dowel holes in the tool.
TYPICAL EXAMPLE7. Remove timing fixture plate (B).8. Fasten a hoist to the fuel injection pump housing and governor. The drive tang on the end of the accessory drive shaft and the slot in the end of the camshaft for the fuel injection pump are not in the center of the shafts. Turn the shaft for the fuel injection pump housing so the slot and the tang will go together.
TYPICAL EXAMPLE9. Put the fuel injection pump housing and governor in the correct position on the accessory drive housing and install bolts (7).10. Install bolts (6).11. Remove the caps from fuel lines (3) and connect them to the fuel injection pump housing. Tighten the fuel lines to a torque of 30 5 lb.ft. (40 7 N m).12. Install tube (2) and breather tube (4).13. Connect the cable and air line to the air fuel ratio control and connect governor control rod (5).14. Remove tool (A) and bolt (1). Install plug in flywheel housing and install the electric starting motor.15. Turn the fuel valve to "ON" position.16. Install the crankcase guard and the hood.