811639 Mercruiser COIL

Start By:a. remove fuel filter base 1. Disconnect fuel lines (1) from the fuel injection pump. 2. Remove six screws, and remove throttle linkage cover plate (2). 3. Place an alignment mark on the throttle shaft and the throttle linkage. Slide the linkage off the shaft. Remove bolts (3). Remove turbocharger oil lines (4) bolt (5), fuel lines (6). Disconnect fuel supply line (7). 4. Remove fuel ratio control line (8). Remove heat shield (9). Label and remove fuel shutoff solenoid wires (10). 5. Remove cover (11) and cover (12). 6. Loosen bolt (13). Leave a gap of 3.2 mm (.125 in.) between the washer and the gear. 7. Use tool (A) to remove gear (14). 8. Fasten a strap and a hoist to the fuel injection pump housing and governor. Remove bolts (15), nuts (16), and remove the fuel injection pump housing and governor from the engine. The weight of the fuel injection pump housing and governor is approximately 26 Kg (58 lb.).Install Fuel Injection Pump Housing And Governor (Later)
1. Put O-ring seals (17) and (18) in position on the fuel injection pump housing and governor. Put clean oil on the O-ring seals. 2. Position the fuel injection pump housing and governor on the oil manifold and the timing gear plate. Fasten with bolts (15) and nuts (16). 3. 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.a. Loosen hose clamps (19), bolt (20), and remove the breather from the valve cover. b. Remove the plug from the flywheel housing.c. Turn the crankshaft clockwise (as seen from the front of the engine) until a 3/8"-16 NC bolt (21) at least 2.5 in. long can be installed in the flywheel through the hole in the flywheel housing. Do not turn the crankshaft counterclockwise. The rocker arms for No. 1 piston can be seen through the breather hole in the valve cover.d. 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 bolt (21) 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.e. If both rocker arms can not be moved by hand, the No. 1 piston is not at top center on the compression stroke. Remove bolt (21) from the flywheel and turn the crankshaft clockwise 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. 12. Install the gear and bolt (13) on the fuel injection pump camshaft without the washer. 13. Install tooling (A) in the fuel injection pump housing. Push on tool (A) and turn the fuel injection pump camshaft. When tooling (A) slides down into the groove (slot) in the fuel injection pump camshaft, the fuel injection pump is in the No. 1 piston top center position.14. With tool (A) still in position remove the bolt from fuel injection pump camshaft.15. Install the washer and the bolt in the fuel injection pump camshaft. Make sure the washer is installed with the large outside diameter toward the bolt head. Tighten the bolt finger tight only. 16. Install tool (B) on the gear.17. Use two torque wrenches to put a clockwise force of 68 N m (50 lb.ft.) on tool (B) to remove the gear clearance (backlash) while the bolt is tightened to a torque of 270 25 N m (199 18 lb.ft.).18. Check the timing as follows 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 the crankshaft is turned clockwise (as seen from the front of the engine), push on the timing pin (A) 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 (A) is installed in the groove (slot) in the pump camshaft.19. Remove the bolt from the flywheel. 20. Install cover (11) and cover (12). The nuts for cover (11) should be tightened to a torque of 27 7 N m (20 5 lb.ft.). 21. Install fuel ratio control line (8). Install heat shield (9). Connect fuel shutoff solenoid wires (10). 22. Install the throttle linkage housing with bolts (3). Slide the throttle linkage onto the throttle shaft, while keeping marks make during disassembly in alignment. Install turbocharger oil lines (4). Install fuel lines (6) and bolt (5). Connect fuel supply line (7). 23. Install throttle linkage cover plate (2). 24. Connect fuel lines (1) to the fuel injection pump. Tighten the fuel lines to a torque of 40 7 N m (30 5 lb.ft.). 25. Position the breather on the valve cover. Tighten hose clamp (19). Tighten bolt (20) to a torque of 14 3 N m (10 2 lb.ft.).End By:a. install fuel filter base.Disassemble Fuel Injection Pump Housing
For removal of the governor from the fuel injection pump housing, see Disassemble Governor. 1. Remove cover (1). 2. Install tooling (B). Engage the timing pin in the center groove of the fuel rack. Move the fuel rack in the direction of the arrow to find the center groove.3. Install tooling (D), and remove bushing (2). 4. Install tooling (E), and remove the fuel injection pump. 5. Remove spacer (3). Do not mix components from fuel injection pump assemblies.6. Remove the remainder of the fuel injection pumps and spacers with Steps 2 through 5 done again