865507A02 Mercruiser COVER ASSEMBLY, Top

1. Disconnect four fuel lines (1).2. Disconnect connector (2). 3. Disconnect two fuel lines (4).4. Remove wire (5).5. Disconnect two connectors (3). 6. Disconnect hose (6).7. Disconnect four connectors (7). 8. Remove two bolts (8).9. Remove eleven bolts (11).10. Remove bracket (9) and cover (10) together. 11. Remove four bolts (14) and spacer (12). At assembly, torque bolts (14) for 5/8" bolts to 230 15 N m (170 11 lb ft) or for 1/2" bolts to 136 7 N m (100 5 lb ft).12. Remove drive gear assembly (13). 13. Remove three bolts (15).14. Remove bolt (16).15. Remove bracket (17). 16. Remove tube (18). 17. Remove three bolts (21).18. Remove bolt (20) and bracket (19). 19. Attach a hoist to pump (22) as shown. Remove the pump. The weight of the pump is 91 kg (200 lb). Reverse the order of Steps 1 thru 19 for installation.End By:a. install fuel injection linesDisassemble Governor & Fuel Injection Pump Housing
Start By:a. remove governor and fuel injection pump housing 1. Remove two bolts (2) and remove rotary solenoid (1). 2. Remove seven bolts (3) and cover (5).3. Remove four bolts (6) and housing (4). 4. Remove fuel shut-off solenoid (9) and the seal with tool (F).5. Remove retainer nut (8). Remove connector (10). 6. Remove two bolts (11) and lever group (12). 7. If necessary, remove spring (14) from lever group (13). 8. Remove jam nut (15) with tool (A).9. Remove control group (16) from the housing. If necessary, remove and replace the O-ring seal. 10. Remove spring (17) from the control group. 11. Remove retaining ring (20) and shaft (18).12. If necessary, remove spring (19). 13. If necessary, remove retaining ring (21) and lip seal (22). 14. Remove four bolts (24), rotary servo group (23), and the gasket from the housing. 15. Remove two bolts (25), cover (26), and the gasket. 16. Remove spring (27) and valve (28) from the rotary servo body.17. Remove bolt (29) and body assembly (30). 18. Remove three O-rings (31) and shaft assembly (32). 19. Separate shaft (36) from star gears (33) and (34).20. Remove key (35), if necessary. 21. Remove two bolts (38) and fuel transfer pump (37). 22. Remove eleven bolts (39) and drive housing (40). 23. Remove bolt and washer (41). Remove rack control bar (42). 24. Remove two bolts (43) and servo piston assembly (44). 25. Remove retaining ring (45), spring seat (46), link spring (47), rack control sleeve (48), and ring (49) from servo piston assembly (44). 26. Remove sleeve (52), piston (51), and valve (50) from servo piston assembly (44). Remove the O-ring seal from sleeve (52). 27. Remove two bolts (53) and pump drive gear (54). 28. Remove the bolt and plug (58) and rack link (57).29. Remove two bolts (56), support assembly (55) and the pin. 30. Loosen twelve washers (59) with tool (B). 31. Install two rack zero pins, tool (E) in the pump housing. Hold the racks against tool (E).32. Install tool (C) and compress the fuel pump spring. Remove twelve washers (59). 33. With the regulator racks held against tool (E) install tool (G), and remove twelve fuel injection pumps (60). Mark each fuel injection pump so the pump can be returned to the original location assembly. Do not handle or mark the internal finishes of the fuel injection pumps. This will cause damage to the pumps. 34. Mark for identification at assembly right and left hand rack regulators (61). Remove the rack regulators. 35. Remove six bolts (62), two bolts (63), the plate assembly, and the gasket from the fuel injection housing.
Typical Example36. Remove bypass valve (64) and the O-ring seal. If necessary, press out adapter (65). 37. Remove bypass valve assembly (66) from valve body (70).38. Remove O-ring seal (67) from bypass valve assembly (66).39. Remove spring (68) and bypass valve (69) from housing (70). 40. Use a seal pick to remove valve lifters (71) and the spacers. Put identification on each of the spacers and lifters as to the location of each part in the pump housing. 41. Remove two bolts (72) and the locking tabs.42. Remove camshaft lock (73). Do not damage the camshaft bearings as the camshaft is removed.43. Remove camshaft (74) from the fuel injection pump housing. 44. If necessary, use tooling (C) to remove camshaft bearings (75).45. If necessary, remove fourteen bolts (76), the cover, and the gasket from each side of the fuel injection pump housing.Assemble Governor & Fuel Injection Pump Housing
1. If removed, install camshaft bearings (75) with tool (C). See the Specifications - 3412 Industrial Engines Manual (SENR4651), for proper location and orientation of bearings.2. If removed, install fourteen bolts (76), the cover and the gasket to each side of the fuel injection pump. Tighten bolts (76) to 14 4 N m (10 3 lb ft). 3. Install camshaft (74) to the fuel injection pump. 4. Install camshaft lock (73).5. Install two bolts (72) and the locking tabs. 6. Put clean engine oil on lifters (71). Install lifters (71) and the spacers in their original locations. 7. Coat O-ring seal (67) with clean engine oil. Install O-ring (67) to bypass valve assembly (66).8. Install spring (68) and bypass valve (69) to valve body (70).9. Install bypass valve assembly (66) to housing (70). 10. Coat the O-ring seal with clean engine oil. Install the O-ring seal and bypass valve (64). If removed, press in adapter (65).