805225A 1 Mercruiser FUEL INJECTOR

Start By:a. remove fuel injection linesb. remove belt tightener1. Remove the hood from the tractor, and remove the guard assembly from the right side of the engine. 2. Remove the bolt and guard (1) from the engine.3. Remove the three bolts, nuts and spacers that hold shield (2) in place on the exhaust elbow. Remove shield (2). 4. Remove the bolts and clips (4) that hold tube assemblies (3) and (5) together.5. Remove oil supply tube assembly (3) and oil drain tube assembly (5) from the turbocharger and cylinder block.6. Put identification marks on lever (7) and the governor shaft for assembly purposes. Loosen the bolt and remove lever (7) from the governor shaft.7. Disconnect hose assembly (9) and tube assembly (6) from the fuel injection pump housing.8. Disconnect tube assemblies (8) from the fuel transfer pump. 9. Disconnect tube assemblies (6) and (8) from the fuel filters.10. Remove bolt (10) and move bracket (11) away from the elbow. 11. Remove bolt (15) and elbow (18) from support (17).12. Remove two bolts (12) that hold support (17) to the governor housing.13. Remove bolt (19) and the clip from the support.14. Remove bolts (13), (14) and (16) that hold support (17) to the engine, and remove the support. 15. Remove six nuts (21) and cover (22) from the timing gear cover.16. Remove the two bolts and heat shield (20) from the engine. 17. Loosen bolt (23) until there is approximately 3.18 mm (.125 in) gap between washer (24) and the fuel pump drive gear.18. Install tooling (A) as shown, and loosen the fuel pump drive gear from the taper on the fuel injection pump camshaft. Remove tooling (A), bolt (23), washer (24) and fuel pump drive gear (25). 19. Fasten a nylon strap and hoist to fuel injection pump housing and governor (26) as shown.20. Remove three nuts (27) that hold the fuel injection pump housing and governor to the timing gear plate. Remove fuel injection pump housing and governor (26) from the engine. The weight of the fuel injection pump housing and governor is 26 Kg (58 lb).Install Fuel Injection Pump Housing And Governor
Typical Example1. Put O-ring seals (28) and (29) in position on the fuel injection pump housing and governor. Put clean engine oil on the O-ring seals. 2. Fasten a nylon strap and hoist to fuel injection pump housing and governor (26) as shown.3. Put the fuel injection pump housing and governor in position on the timing gear plate, and install nuts (27) on the studs to hold it in place. 4. Remove bolts (31) and cover (30) from the fuel injection pump housing. 5. Install the bolt that holds the fuel pump drive gear to the fuel injection pump camshaft without the washer. This will allow the camshaft in the fuel system to be turned.6. Install tooling (A) in the fuel pump housing as shown. Put pressure on the end of tool (A), and turn the camshaft slowly until tool (A) drops into the groove (slot) in the camshaft. The fuel injection pump is in the No. 1 piston top dead center position. 7. With tooling (A) still in position, remove the bolt from the fuel injection pump camshaft.
Do not over tighten bolt (23) that holds the drive gear on the fuel injection pump. If the bolt is too tight, the gear will not be allowed to slip on the fuel injection pump shaft. This will cause the timing pin to break off in the notch of the camshaft when the flywheel is turned.
8. Install washer (24) and bolt (23) in the fuel injection pump camshaft with the large diameter of the washer toward the bolt head. Tighten the bolt to a torque of 6.8 N m (60 lb in).9. Remove the electric starting motor. See the topic, Remove Electric Starting Motor in this module. Install tooling (B) in the flywheel housing. Make sure bolt (23) does not loosen as the flywheel is turned.10. Use tooling (B), and turn the flywheel in the direction of engine rotation, (clockwise from the front of the engine), until bolt (32) 3/8 [" - 16 NC x 4 in. (102 mm) long] can be installed in the flywheel. Do not turn the crankshaft counterclockwise to get the bolt aligned with the hole in the flywheel.11. If you go past the bolt hole in the flywheel, turn the crankshaft counterclockwise opposite the direction of engine rotation (as seen from the front of the engine) approximately 30 degrees. This procedure will permit the gear clearance (backlash) to be removed from the timing gears when the crankshaft is turned in the direction of engine rotation (clockwise).12. Repeat Step 10 again. The rocker arms for No. 1 piston can be seen through the breather hole in the valve cover.13. Loosen clamp (33) and bolt (34) that hold the breather cap to the valve cover. Remove breather cap (35) and the 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 backward and forward by hand (have clearance with the valve stem).14. When both rocker arms are loose, tighten bolt (23) that holds the fuel pump drive gear to the fuel injection pump camshaft to a torque of 270 25 N m (200 18 lb ft).15. Remove tooling (A) and (B) and bolt (32) from the flywheel.16. Put the O-ring seal and breather cap (35) in position on the valve cover and the hose. Tighten hose clamp (33), and install bolt (34). Tighten the bolt to a torque of 14 3 N m (10 2 lb ft).17. Install the electric starting motor. See the topic, Install Electric Starting Motor in this module. 18. If studs (36) were removed, put 5P3413 Pipe Sealant with Teflon on them, and install them in the timing gear cover.19.