806409 Mercruiser ELBOW

start by:a) remove mufflerb) remove fuel ratio controlc) remove fuel injection linesd) remove fuel transfer pumpe) remove fuel shutoff solenoid1. Put the fuel injection pump in correct timing with the engine as follows: a) Turn the engine flywheel with tool (A) to put No. 1 piston at top center compression stroke. b) Install tool (B) in the fuel ratio control opening to engage with the timing groove in the fuel injection pump camshaft. See FINDING TOP CENTER COMPRESSION POSITION FOR NO. 1 PISTON AND CAMSHAFT TIMING FOR THE FUEL INJECTION PUMP in TESTING AND ADJUSTING.2. Remove the cotter pin and pin (1) that hold governor control cable (3).3. Loosen the nut that holds cable (3) to the engine bracket and remove the cable from the bracket.4. Disconnect fuel lines (2) from the governor plate.5. Remove the vee belt set from the fan drive and disconnect the spring from the belt tightener.6. Remove the cover and gasket from the automatic timing advance housing. 7. Remove the four bolts and retainer (4) that hold the automatic timing advance to the fuel pump camshaft.
Do not let the retainer drop in the housing.
8. Remove brackets (5) and bolts (6) from each side of the fuel injection pump housing.9. Pull the fuel injection pump housing out of the timing gear housing.10. Install a 5/16"-18 NC forged eyebolt and a 3/8"-16 NC forged eyebolt in the fuel injection pump housing as shown. Fasten a hoist to the fuel injection pump housing and governor and remove it from the engine. Weight of the fuel injection pump housing and governor is 110 lb. (50 kg). 11. Inspect the two O-ring seals on the bottom and seal (7) on the front of the fuel injection pump housing. If the seals have damage, use new parts for replacement.
Do not cause damage to the oil inlet and outlet dowels on the bottom of the fuel injection pump housing.
Install Fuel Injection Pump Housing And Governor
Make sure there is no paint, dirt or foreign material on the machined surface of the fuel injection pump housing and the machined surface of the cylinder block. The surfaces must be clean before the fuel injection pump housing and the machined surface of the cylinder block. The surfaces must be clean before the fuel injection pump housing is installed.
1. Turn the fuel injection pump camshaft until tool (A) can be installed in the groove of the fuel injection pump camshaft.2. Put 5P960 Multipurpose Grease on the O-ring seals. Install the two seals on the bottom of the oil inlet and oil outlet dowels. Install the seal on the front of the housing.3. Fasten a hoist to the fuel injection pump housing and governor. Put the unit in position on the engine. Make sure the fuel injection pump housing is in the automatic timing advance unit and the bolt holes in the fuel injection pump housing are in alignment with the bolts holes in the engine. Install the bolts and brackets that hold the unit in position. Make sure the automatic timing advance unit is in correct position on the fuel pump camshaft.4. Install the retainer and the bolts that hold the automatic timing advance unit on the fuel pump camshaft. Tighten the bolts to a torque of 50 lb. ft. (70 N m) with the timing pin in the fuel pump camshaft.5. Remove the timing pin and tighten the bolts to a torque of 100 5 lb. ft. (135 7 N m) 6. Install the gasket and cover (1) for the automatic timing advance. 7. Put spring (3) in position on the belt tightener and install pin (4) and the cotter pin to hold it.8. Install vee belt set (2) for the fan drive. 9. Connect the governor control cable (6) to lever (5) with pin (8) and the cotter pin.10. Make sure governor control cable (6) is in position in the bracket and tighten nut (7).11. Connect the fuel lines to the governor plate.end by:a) install fuel shutoff solenoidb) install fuel transfer pumpc) install fuel injection linesd) install fuel ratio controle) install muffler