809891 Mercruiser HEAD ASSEMBLY, Cylinder

start by:a) remove fuel injection linesb) remove firewallc) remove precleaner and air cleaner (left side, later machine only) 1. Remove plate (1) from the left side of the flywheel housing. Bolt (2) is also the timing bolt for the flywheel. Some engines do not have the nut welded on the retainer. Use Step 2 on these engines. 2. There are two ways the engine can be turned. The first way is as follows: a) Remove bolts (4) that hold pinion (3) and spacer (5) to the flywheel housing.b) Install pinion (3) in the flywheel housing. Use a 1/2" ratchet and turn the engine.3. The second way is as follows: a) The retainer (6) that holds the vibration damper and hub on the crankshaft has a 1 1/8" nut welded to it.b) Use a 1 1/8" socket and turn the engine. This will take two persons to do this procedure.4. Turn the engine clockwise (as seen from the flywheel) approximately 30° to remove the plug in the timing gears. Turn the engine counterclockwise (as seen from the flywheel) until the threaded hole in the flywheel is in alignment with the hole in the flywheel housing and bolt (2) can be installed in the flywheel. The No. 1 piston is at top center compression stroke.5. The intake and exhaust valves for No. 1 cylinder on the right side of the engine must be free to move by hand. If not, it will be necessary to turn the engine counterbore (as seen from the flywheel) 360° more and install bolt (2) again. If the hole in the flywheel is turned beyond the hole in the flywheel housing, turn the engine clockwise (as seen from the flywheel) a minimum of 30° before the engine is turned counterclockwise (as seen from the flywheel) to install bolt (2).6. Disconnect the governor control linkage from the governor lever. 7. Remove the speed limiter access plug from the governor. Loosely install 9S8519 Plug (7) [part of tooling (A)]. Install 9S8521 Rod (8) [part of tooling (A)] and push in the speed limiter plug. Tighten plug (7). This will let the governor control lever move through its complete length of travel. 8. Remove timing pin (9) from storage hole (10) and install it in timing hole (11) in the fuel injection pump. Move the governor control lever until the timing pin goes through the notch in the rack. Push the timing pin into the fuel injection pump housing. If the timing pin goes into the timing groove (slot) in the fuel pump camshaft, the flange of the timing pin will be against the fuel injection housing.9. If the timing pin does not go into the fuel injection pump camshaft, see CHECKING MOVEMENT OF THE VARIABLE TIMING UNIT and ADJUSTING VARIABLE TIMING UNIT DRIVE GEAR in TESTING AND ADJUSTING.
EARLIER MACHINE ONLY Steps 10 through 12 are for earlier machines only.10. Remove tube assembly (12) from bracket (14) and the turbocharger.11. Remove tube assembly (13) from bracket (14) and the turbocharger.12. Remove bracket (14).
LATER MACHINE ONLY13. Remove cover (15) from the engine.
Make sure the timing pin is removed from the fuel injection pump housing before the bolts, locks and gear (8) are removed.
14. Bend lock (16) away from the bolts.15. Remove the bolts, lock and retainer (17).16. Remove gear (18).
EARLIER MACHINE ONLY Steps 17 through 19 are for earlier machines only.17. Remove channel (20).18. Remove bar (19).19. Disconnect the hose assembly (not shown) from the nozzle (not shown) for the fire suppression system.
LATER MACHINE ONLY Steps 20 and 21 are for later machines only.20. Remove bolt (22) and loosen bolt (21). Move bar (23) out of the way. 21. Remove plate (24) from the muffler mounting brackets.
LATER MACHINE SHOWN22. Remove tube assembly (25).23. Remove bolts (26) from the bracket.24. Disconnect wires (27) for the solenoid.
LATER MACHINE SHOWN25. Remove bracket (28) from the rear of the fuel injection pump housing and cylinder head.
LATER MACHINE SHOWN26. Disconnect wire (29) from the terminal on the right cam base housing.27. Remove bracket (30) and move the wires out of the way. Step 28 is for later machines only.28. Remove bracket (31) for the fire suppression hose.
EARLIER MACHINE SHOWN29. Disconnect tube assembly (32) from the fuel transfer pump.30. Disconnect tube assembly (34) from the fuel transfer pump.31. Disconnect tube assemblies (33) and (35) from the adapter.32. Remove tube assembly (36) from the fuel transfer pump and the cylinder block.
EARLIER MACHINE SHOWN33. Remove bolts (37) and brackets (38) that hold the fuel injection pump housing to the engine.
EARLIER MACHINE SHOWN34. Install four 3/8"-16 NC forged eyebolts (39) in the fuel injection pump housing.35. Fasten a hoist and move the assembly forward to clear the O-ring seal at the rear of the pump housing. Remove the fuel injection pump housing, governor, fuel transfer pump and adapter as a unit. Weight is 230 lb. (104 kg).Install Fuel Injection Pump Housing, Governor, Fuel Transfer Pump And Adapter
EARLIER MACHINE SHOWN1. Put 1P808 General Purpose Lubricant on the O-ring seal on the fuel injection pump housing. Use a hoist to put the fuel injection pump housing, governor, fuel transfer pump and adapter (1) in position on the engine. Move the assembly toward the rear of the engine. Make sure the O-ring seal makes a seal in the cylinder block and is not damaged.2. Remove the hoist and the forged eyebolts.