48363 Mercruiser GASKET, Valve Guide

1. Remove plug (2) from the fuel injection pump housing. 2. Pull rack (1) toward the governor end of the fuel injection pump housing. Install tool (B) in the pump housing. Hold tool (B) in against the rack and push the rack back toward the drive end of the pump housing until the notch in the rack comes in contact with tool (B). The rack is now in the center position. Install clip (3), part of tooling (A), to hold the rack in the center position against tool (B).
The rack must be in the center (zero) position before the fuel injection pumps can be removed. Make a note of the location of each fuel injection pump so it can be installed in its original location in the pump housing.
3. Remove the cap and soft washer from the top of the fuel injection pump. 4. Install tool (C) and remove bushing (4) and the O-ring seal below the bushing. 5. Install tool (D) on bonnet (5) of the fuel injection pump and remove the fuel injection pump from the pump housing.Install Fuel Injection Pumps
The rack must be in the center (zero) position before the fuel injection pumps can be installed. See Step 2 of the fuel injection pump removal procedure to put the rack in the center position.
1. With the rack in the center position, install the fuel injection pumps as follows: a) Turn the camshaft until the lobe of the camshaft is down for the pump to be installed.b) Install tool (D) on the pump.c) Put the groove (1) in the barrel in alignment with the groove (2) in the pump gear segment. Put the pump in position so the grooves are in alignment with the guide pins in the housing and lifter. Install the pump in its correct position in the housing. d) Install the O-ring seal and bushing (3) over the bonnet. Install tool (C) on the bonnet and push down on tool (D). Tighten bushing (3) by hand until the bushing is even with the top of the housing. If the installation of the bushing can not be made this far by hand, remove it. Remove the pump, put the parts in alignment again and install the bushing again.
If installation of pump is correct, the bushing can be tightened by hand until it is even with the face of the pump housing. The fuel injection pump, the housing or the lifter will be damaged if force is used to install the bushing until it is even with the face of the pump housing.
e) Check the rack travel after each pump is installed as follows: Move the clamp, part of tooling (A), away from the end of the rack and remove timing pin (B) from the fuel injection pump housing. Install tooling (A) and (E) on the pump housing as shown to measure rack movement. Hold rack (4) against the stem in tool (E) when the measurement is made. The total rack movement must be 20.32 mm (.800 in.). If the rack can not be moved this distance, the pump gear segment is not in the correct position and the pump must be removed and installed again. 2. After all the fuel injection pumps are installed, remove tooling (A) and (E). Install the plug in the hole for timing pin (B). Use tool (C) to tighten bushing (3) to a torque of 205 14 N m (150 10 lb.ft.). Remove tool (C). Install the soft washers and protection caps for the fuel injection pumps.end by:a) assemble governorb) install fuel injection pump housing and governorc) adjust the governor and set the rack (See GOVERNOR ADJUSTMENTS and FUEL RACK SETTING in TESTING AND ADJUSTING)Disassemble Fuel Injection Pumps
start by:a) remove fuel injection pumps
Be careful when the fuel injection pumps are disassembled. Do not damage the surfaces of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. The check assemblies are made as a set. Do not mix the parts of the different check assemblies. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.
1. Remove ring (1) and make a separation of bonnet (2) and barrel (3). 2. Remove spring (4) and check assembly (5) from the bonnet. 3. Remove plunger (8) and washer (7) as a unit from spring (6) and the barrel. Remove washer (7) from the plunger. Remove spring (6) from the barrel.
Do not remove the gear from the plunger. The gear and plunger are assembled and adjusted at the factory.
Assemble Fuel Injection Pumps
Put clean fuel oil on all parts during assembly.
1. Install spring (2) on barrel (1). Install washer (3) on plunger (4) with the flat side toward the gear. Install plunger (4) in barrel (1) and engage washer (3) in spring (2). 2. Install spring (5) and check assembly (6) in bonnet (7).
Do not slide bonnet (7) across the face of barrel (1) when ring (8) is installed. The check assembly in the bonnet can put scratches in the face of barrel (1).
3. Put bonnet (7) in position on barrel (1) and install ring (8) to hold the bonnet and barrel together.end by:a) install fuel injection pumps