808483 Mercruiser CAP

Start By: a. remove the fuel injection linesb. remove the fuel transfer pump1. Disconnect line (1) to fuel ratio control.2. Remove bolts (2) and remove fuel primer.3. Disconnect governor control linkage at pin (3) and remove hose (4). 4. Remove fuel filter (5), disconnect the wires and remove switch (6).5. Remove six nuts and remove cover (7). 6. Loosen bolt (9) on fuel pump drive gear, loosen bolt until a gap of 3.18 mm (.125 in.) is between washer and gear. Install tooling (A) and pull drive gear loose from the shaft. Remove tooling (A), remove bolt and washer. 7. Remove bolts (10) and nuts (11). Use two persons to remove fuel injection pump housing and governor. The weight of the fuel injection pump housing and governor is 29.5 kg (65 lbs.). Install Fuel Injection Pump Housing and Governor
1. Make sure the four O-rings are in place. Using two people, position the fuel injection pump housing and governor, install nuts (11) and bolts (10). 2. Remove bolts (12) and cover (13) with the gasket.3. Position tooling (A), install bolt (9) that holds the gear to camshaft, without a washer. This will allow the camshaft to be turned. 4. Put pressure on the end of tooling (A) and turn the camshaft slowly until the tool drops into the groove (slot) in the camshaft. Leave tool (A) in position in the groove (slot). Remove the bolt from the end of the camshaft.5. Install washer and bolt (9), tighten it to a torque of 6.8 N m (60 lb. in.). 6. Install tooling (B) as shown in the flywheel housing.7. Use tooling (B), and turn the flywheel in the direction of engine rotation until bolt (14) [2/8" - 16 NC × 4 in. (102 mm) long] can be installed in the flywheel. Do not turn the crankshaft counter clockwise to get the bolt hole alignment.8. If you go past the bolt hole in the flywheel, turn the crankshaft counter clockwise, opposite the direction of engine rotation (as seen from the front of the engine) approximately 30 degrees. This procedure will permit the backlash (gear clearance) to be removed from the timing gears when the crankshaft is turned in the direction of engine rotation (clockwise).9. Loosen the clamp and bolt that hold the breather cap to the valve cover. Remove the breather cap and O-ring seal from the valve cover. 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 by hand (have clearance with the valve stem).10. When both rocker arms are loose, tighten bolt (9) to a torque of 270 25 N m (199 18 lb. ft.).11. Remove tooling (A) and (B) and bolt from the engine.12. Install O-ring and breather cap on valve cover.13. Install cover (7) and nuts. Install fuel filter (5) and switch (6). Connect wires.14. Connect hose and connect line. Install the fuel primer and the bolts. Connect governor control linkage. End By: a. install fuel transfer pumpb. install fuel injection lines