809077 Mercruiser GASKET (ALL)

1. Remove nuts (1), cover (2), and the gasket. 2. Put No. 1 piston at the top center compression position (TC) with the following procedure:a. Remove plug (3), two bolts and cover (2) from the flywheel housing. b. Install Tool (B) in the flywheel housing. Use Tool (B) to slowly rotate the engine in the direction of normal rotation, (counterclockwise as seen from the flywheel end of the engine), until timing bolt (4) can be installed in the flywheel housing and into the hole in the flywheel. c. Remove the valve cover from the valve cover base. Check to see if both rocker arms (5) for the No. 1 cylinder can be moved backward and forward. The No. 1 piston is at the top center compression position (TC) when the timing bolt is installed in the flywheel and both rocker arms for the No. 1 cylinder can be moved backward and forward. If both rocker arms cannot be moved, the No. 1 piston is not at the top center compression position (TC). Remove the timing bolt from the flywheel and rotate the engine in the direction for normal rotation, (counterclockwise as seen from the flywheel end of the engine one full turn 360 degrees, and install the timing bolt again.3. Remove the timing bolt, and use Tool (B) to rotate the engine in the opposite direction of normal rotation (clockwise as seen from the flywheel end of the engine) a minimum of 30 degrees. The timing is correct if Tool (A) and the timing bolt can be installed at the same time. The timing procedure in the Testing & Adjustment Manual must be done again if the timing bolt and Tool (A) can not be installed at the same time.4. Remove the plug from the timing pin hole in the fuel injection pump housing. Install Tool (A) in the timing pin hole. 5. Remove eight bolts (6) and automatic timing advance (7). 6. Remove gear (9) from fuel injection pump camshaft (8).The following steps are for the installation procedure.7. Install gear (9) on fuel injection pump camshaft (8). 8. Install two 3/8 in 16 NC x 6 in (152.4 mm) long guide bolts (10). Space the guide bolts evenly.
There is a light spring located beneath the flyweight cover (12). Hold cover (12) while removing last nut (11). Slowly remove flyweight cover (12) to avoid dropping the spring.
9. Remove four nuts (11) and remove flyweight cover (12). 10. Put automatic timing advance (13) in position on the fuel injection pump camshaft, and install four bolts (14). Tighten bolts (14) just past finger tight. Remove guide bolts (15). 11. Install four nuts (16). Install Tool (C). 12. Tighten four knurled nuts (17) finger tight.
Do not use any tools to tighten the knurled nuts.
13. Install all mounting bolts (14) and tighten to 55 10 N m (41 7 lb ft).14. Loosen knurled nuts (17). Remove four nuts (16) and remove Tool (C).15. Install the spring and flyweight cover (12). Install four nuts (16). Tighten nuts (16) to a torque of 6 1 N m (53 9 lb in).16. Install a gasket and timing advance cover (2). Tighten eight nuts (1) to a standard torque.17. Remove timing pin (A) and replace the plug in the fuel pump housing.18. Remove timing bolt (4) and replace the plug. Install cover (2) on the flywheel housing.19. Check the dynamic timing curve. See Testing & Adjusting Manual SENR6471 for the proper specifications.Disassemble Automatic Timing Advance
Start By:a. remove automatic timing advance 1. Remove four nuts (1) and remove retainer (2) from automatic timing advance. 2. Remove spring (3) and race (4). 3. Remove four cap screws (5), two retainer plates (6) and remove carrier group (7) from automatic timing advance. 4. Remove snap ring (8), tapered race (9), spool (10) and weights (11) from carrier (7). 5. Remove race (12) from carrier (7). 6. Remove four bolts (13). 7. Remove plate (14), ring (16) and ring (17) from carrier assembly (15). Remove seals (19) and (20) from carrier assembly (15). Remove seal (18) from plate (14).Assemble Automatic Timing Advance
1. Install new seals (18), (19) and (20). 2. Lubricate seal (18), (19) and (20) with engine oil then carefully install carrier assembly (15) into ring (17). Install ring (16) and plate (14). 3. Align proper bolt holes and install four bolts (13). 4. Position race (12) into carrier (7).5. Position weights (11), spool (10), tapered race (9) and snap ring (8) into carrier (7). 6. Lubricate spool (10) and lower it into position in the automatic timing advance. Position retainer plates (6) and install four cap screws (5). Tighten cap screws (5) to a torque of 3.4 0.4 N m (30 4 lb in). 7. Position race (4) and spring (3). When installing retainer (2), be sure spring (3) properly engages retainer adjustment screw.8. Position retainer (2) and install four nuts (1).End By:a. install automatic timing advance