808490 Mercruiser DRIVE GEAR

START BY: a. remove timing gear cover 1. Loosen bolt and washer (1) that hold fuel injection pump drive gear (2) to the fuel injection pump camshaft until the washer is approximately 3.20 mm (.125 in.) from the gear. Do not remove the bolt and washer at this time.2. Install tooling (A) on the drive gear. Tighten the screw in tooling (A) until the drive gear is loose. Remove tooling (A), bolt and washer (1) and drive gear (2). 3. Remove bolt (3), the lock and washer and idler gear (4). 4. Remove bearing (5) from the idler gear with tooling (B). 5. Turn the crankshaft until "C" marks (7) on crankshaft drive gear (8) and camshaft drive gear (6) are in alignment with each other.
Do not turn the crankshaft after the camshaft drive gear has been removed. Damage to pistons or valves or both can result.
6. Remove bolts (9) and camshaft drive gear (6) from the camshaft. 7. Remove three nuts (10) from the studs that hold the fuel injection pump housing to the timing gear plate. 8. Remove bolts (12) and timing gear plate (11) from the cylinder block.Install Timing Gears And Plate
1. Clean the old gasket from the contact surfaces of the timing gear plate and the cylinder block. Install a new gasket on the cylinder block. Cut the gasket even with the bottom face of the cylinder block. Put 5H2471 Cement on the bottom of the gasket where the gasket makes contact with the gasket for the oil pan. 2. Be sure O-ring seals (1) are in position on the end of the fuel injection pump housing.3. Put timing gear plate (2) in position on the cylinder block. Install the four bolts that hold the plate in place. Install the three nuts that hold the fuel injection pump housing to the back of the timing gear plate. 4. Install camshaft drive gear (4) on the camshaft so the "C" marks on both camshaft drive gear (4) and crankshaft drive gear (3) are in alignment. Install the bolts that hold camshaft gear drive (4) on the camshaft. Tighten them to a torque of 55 7 N m (41 5 lb.ft.). 5. Install the bearing in idler gear (5) with tooling (A). The end of the bearing must be 1.5 0.5 mm (.06 .02 in.) below the surface of the gear hub. 6. Be sure the oil hole in shaft (6) for idler gear (7) is open. Put idler gear (7) in position on the shaft, and install the washer, lock and bolt that hold the gear on the shaft. 7. Put fuel injection pump drive gear (8) in position on the fuel injection pump camshaft. Install the washer and bolt that hold the gear in place, but do not tighten the bolt at this time. The flat side of the washer must face away from the gear. For correct installation of the fuel injection pump drive gear and timing of the engine, see Install Fuel Injection Pump Housing And Governor.END BY: a. install timing gear cover