805435A 1 Mercruiser FUEL LINE

Start By:a. remove flywheel housing1. Remove the nut and washer that hold the yoke to the accessory drive, and remove the yoke. 2. Remove the bolts and adapter assembly (3) from the flywheel housing. Remove O-ring seal (4) from the adapter assembly.3. Remove the lip-type seal from the adapter assembly.4. If necessary, remove the bearing from adapter assembly (3) with tool (A).5. Remove washer (2) from shaft (1). 6. Remove the bolts that hold shaft (1) to gear (5), and remove the shaft 7. Remove gear (5) from the flywheel housing.8. Remove washer (6) from cage assembly (7). 9. Remove the bolts and cage assembly (7) from the flywheel housing.10. If necessary, remove two dowels (8) and bearing (9) from the cage assembly. 11. Remove the nuts from the studs in shaft (13). Remove the shaft from gear assembly (10).12. Remove washer (11) and O-ring seal (14) from the shaft.13. Remove gear assembly (10) from the flywheel housing.14. If necessary, remove bearing (12) from gear (10) with tool (B).15. Remove the washer from the flywheel housing. The following steps are for installation of the accessary drive.16. Install the washer on the dowels in the flywheel housing. Install the washer with the small dowel hole toward the top of the flywheel housing.17. If the bearing was removed from gear (10), install bearing (12) in the gear with tool (B). Install the bearing until it is 1.0 0.5 mm (.04 .02 in) below the surface of the small gear. The inside diameter of the bearng must be 94.000 0.055 mm (3.7007 .0022 in) after installation.18. Install gear (10) in the flywheel housing with the small diameter gear toward the flywheel side of th housing.19. Put O-ring seal (14) and washer (11) in position on shaft (13). Put clean engine oil on the O-ring seal. Tighten the studs in shaft (13) to a torque of 100 15 N m (75 11 lb ft).20. Put shaft (13) in position in gear (10) and the flywheel housing.21. Put 5P3413 Pipe Sealant with Teflon on the nut end of the studs in shaft (13). Install the washers and nuts to hold the shaft in place. Tighten the nuts to a torque of 200 25 N m (160 18 lb ft).22. If bearing (9) was removed from cage assembly (7), align the hole in the bearing with the hole in the cage, and install the bearing in the cage assembly with tool (B). Install the bearing until it is 1.0 0.5 mm (.04 .02 in) below the surface. The inside diameter of the bearing must be 63.500 0.038 mm (2.5000 .0014 in) after installation.23. If dowels (8) were removed from the cage assembly, install the dowels until they are 3.5 0.5 mm (.14 .02 in) above the surface of the cage assembly.24. Put cage assembly (7) in position in the flywheel housing, and install the bolts that hold it. 25. Put washer (6) in position on the dowels in cage assembly (7).26. Install gear (5) in the flywheel housing.27. Put shaft (1) in position in gear (5), and install the bolts that hold the shaft to the gear. Tighten the bolts to a torque of 90 15 N m (65 11 lb ft).28. If the bearing was removed from adapter assembly (3), install the bearing with tool (A). Install the bearing until it is 1.0 0.5 mm (.04 .02 in) below surface (X). The inside diameter of the bearing must be 63.500 0.038 (2.5000 .0014 in) after installation.29. Use tool (A) to install the lip-type seal in the adapter assembly. Install the seal with the lip of the seal toward the bearing.30. Put O-ring seal (4) in position on adapter assembly (3). Put clean engine oil on the O-ring seal and the lip-type seal.31. Put adapter assembly (3) in position on the flywheel housing, and install the bolts that hold it.32. Put the yoke in position on the shaft, and install the washer and nut to hold it. Tighten the nut to a torque of 600 50 N m (440 37 lbft).End By:a. install flywheel housing