865440H68 Mercruiser HOUSING ASSEMBLY, Driveshaft - Complete

1. Use tool (F) and remove the shutdown solenoid (1). 2. Remove two bolts (2) and remove actuator solenoid (3) from the fuel injection pump housing.3. Remove two rack zero plugs (4).
Typical Example4. Push the rack servo (5) toward the rear of the engine. Install tools (A) in the rack zero pin holes. Push the rack servo (5) toward front of the engine and install tool (B) to hold the rack against the rack zero pin. 5. Use tool (C) to loosen bushing (6). 6. Install tool (E) and compress fuel pump spring. Hold tool (E) in position and remove bushing (6).
Typical Example7. Remove fuel injection pump with tool (D).
When injection pumps, spacers, and lifters are removed from the injection pump housing, keep the parts of each pump together so they can be installed back in their original location.
8. Disassemble the fuel injection pump. Remove ring (8). Make a separation of bonnet (7) from the plunger and barrel assembly (9).
Be careful when the injection pumps are disassembled. Do not cause damage to the surface on the plunger. 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. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.
9. Remove the gear segment, the washer, and the spring from the barrel.10. Remove the ring, spring, the collar, and valve from the barrel.
Typical Example11. Remove spacer (10).Install Fuel Injection Pumps
Typical Example Make sure the fuel racks are in the center (zero) position before the fuel injection pumps are installed.1. Install plunger (10) and gear segment (11), washer (5), and spring (9) in position on barrel (4). Put check valve assembly (7), spring (3), and collar (8) in position in bonnet (6). Connect bonnet (6) and barrel (4) together with ring (2). Keep seal (1) with bonnet for use during installation. 2. Put spacer (13) into position in the pump housing bore. Make sure the correct spacer is with each pump.3. Align the space in gear segment (11) with the groove in barrel (4).4. Put the injection pump straight down into the housing bore so the space in gear segment (11) aligns with pin (12) and the groove in barrel (4) aligns with dowel (14). Use tool (C) to install the pump. 5. Install seal (1) and bushing (16) in the pump housing bore. If the pump is in the correct position, install tool (D) with bushing (16). Compress fuel injection pump spring with tool (D) and hand start the bushing threads into the pump housing. Tighten the bushing to a torque of 245 15 N m (180 10 lb ft) with tool (B).6. Check for correct installation of the injection pumps with the engine stopped. See the topic, Injection Pump Installation in the Testing and Adjusting manual.
If one or more of the injection pumps have been installed wrong, damage to the engine is possible if cautions are not taken when the engine is first started. Make preparation to close off the air intake to stop the engine if necessary.
7. Remove the timing pin tool (A), and install the plug in the injection pump housing.End By:a. install fuel lines