19743A 4 Mercruiser BOTTLE ASSEMBLY

Start By:a. remove fuel injection pump housing and governorb. remove fuel ratio control
(Earlier)
(Later)1. Remove fuel shut-off solenoid (1) from housing. 2. Remove five bolts (4) and remove cover (5). Remove bolt (2) then remove cover (3) from high and low idle screws. 3. Remove bolt (7) and remove large cover assembly (6). Remove gasket (8). Be careful not to drop strainer assembly out of bottom of cover assembly. Remove strainer after cover assembly is removed. 4. Bend locks (9) back, then remove four bolts (11) and two levers (10). 5. Remove shaft (13) and washer (12) from large cover assembly. 6. Remove two bearings and two seals (14) from the cover assembly. 7. Remove insulator (15) from cover assembly. 8. Remove bolt (18) from stop collar (16). Remove spring (17) from below collar. 9. Remove bolts (20), then remove governor housing (19). 10. Put a mark on low and high idle screws (21) and make a note of each turn until idle screw makes contact with the bottom. This is done to get the approximate setting for assembly purposes. Remove both idle screws.11. Bend lock and remove two bolts (22). Remove the torque spring group (23). 12. Bend lock down and remove the bolt (26) from control lever (25). Remove shaft (24) and control lever (25). 13. Remove pin (28), then remove spring and plunger. Remove band assembly (27) from control lever. 14. Remove two bearings (29) and two seals (30) from the governor housing.
(Earlier)
(Later)15. Install tool (A) in fuel injection pump housing. Remove three bolts (31) from the governor plate.
(Earlier)
(Later)16. Push on rack with a punch or screwdriver until stop on rack is against tool (A), then remove governor plate (32). 17. Remove seat (33), spring washer (34), flat washer, spring washer (35) and spring (36). 18. Remove spring washer (38). Remove ring (40) from the seat (39). Remove dowel from behind ring (40).19. Remove seat (39) and governor bolt (37) as a unit. Remove governor bolt (37) from seat (39). 20. Remove washer (42), spring (43), the washer and sleeve (41).21. Remove the ring, race, bearing and race from the bottom of sleeve (41).22. Remove lock (44) from flyweight assembly (45). Remove flyweight assembly (45).23. Turn the governor plate over. 24. Bend the locks from bolts (46) and remove the bolts (46). Remove bracket assembly (47). 25. Remove pin and servo piston assembly (48) from the bracket assembly.26. Remove dowel (50), then remove levers (49) and spring from the bracket assembly. 27. Turn the governor plate over again. Hit lightly on the cylinder (51) to remove it from the governor plate. 28. Remove piston (53) from cylinder. Remove sleeve (54) from the cylinder. Remove the O-ring seals from cylinder (51) and seal (52) from sleeve (54). 29. Remove ring (55), then remove dowel from behind ring.30. Remove drive assembly (56).31. Remove snap ring from bottom side of governor plate with tool (B). 32. Remove drive gear (57). 33. Remove three dowels (58) and bearing (59) from the governor plate.
(Earlier)
(Later)34. Remove fuel transfer pump (60) from the fuel injection pump housing. Fuel transfer pump (60) can be done with fuel injection pump housing and governor on engine and engine in vehicle.
(Earlier)
(Later)35. Remove bolts (61) and cover (64). Remove bolts (63) and housing (62). 36. Remove shaft and gear (65) from housing (62). 37. Remove gear (66) from shaft with a press. 38. Remove bushing (67) from housing (62). Bushing (67) will be damaged when removed.
(Earlier)
(Later)39. Remove coupling (122). (Later models). Remove three bolts (69) and retainer (70). Remove pinion gear (68).
Camshaft is now free to slide out, use caution.
40. Remove felt washers (71). Install tools (C) and (D). Remove bushings (72) with tool (C). A small amount of pressure downward on tool (D) sometimes will help in removal of bushing (72). 41. Put identification on each injection pump as to its location in the pump housing. Hold the fuel racks against tool (A) in the center (zero) position and carefully remove each fuel injection pump with tool (D). 42. Remove the bolt that holds bracket (73) to the fuel injection pump housing. Remove bracket (73). 43. Put identification on fuel racks (74) and (76). Remove link (75), then remove fuel racks (74) and (76). 44. Remove spacers (78) and lifters (77) from the pump housing. Put identification on each of the spacers and lifters as to their location in the pump housing. 45. Remove camshaft (79) from the pump housing. 46. Remove bypass valve assembly (80) from the fuel injection pump housing. 47. Remove two O-ring seals (81) from valve (80). Remove pin (82), then remove piston and spring from valve (80). 48. Remove bolts (83), then remove cover (84). When pinion gear (87) is removed, make a replacement of drive gear (86) with a new part. 49. Remove idler gear (85). Remove pinion gear (87) from the pump housing with a soft hammer. Remove drive gear (86). 50. Remove dowel (88), shaft (89) and dowel (90) with tool (F).51. Remove the lower and upper bearings (91) that are supports for the pinion assembly.52. Remove bearing (92) and lip type seal. Remove bearing (93) and lip type seal. 53. Remove rack bearings from locations (94).54. Remove the camshaft