866458J02 Mercruiser HOUSING ASSEMBLY, Driveshaft - Complete

preparatory steps: a) remove fuel injection pump housing, and governor as a unitb) remove safety shutoff and overspeed assembly (Industrial only)c) remove governord) remove variable timing unit 1. Remove the timing pin assembly from its storage position. Install one of the pin retaining bolts upside down through one of the flange holes and tighten with nut. Install the pin assembly into timing hole and move rack back and forth slowly until the timing pin engages slot in rack. Depress timing pin until head of inverted bolt (1) touches housing.
Do not attempt to remove fuel injection pumps if rack is not positioned as outlined above.
2. Remove the safety shutoff control-to-fuel injection pump housing adapter housing (3).3. Identify each of the fuel injection pumps by its location in the fuel injection pump housing. Remove the pump mounting bolts. Pull straight up on each pump to remove it from housing. 4. Disassemble the fuel injection pumps as follows: Using wrench (A), remove the retainer. Remove the valve and spring. Pull the plunger out of the body to remove plunger, washer and spring.
While disassembling fuel injection pumps, exercise considerable care to prevent damage to plunger surfaces. The body and plunger assemblies are matched and are not interchangeable with other bodies or plunger assemblies.
5. Remove the cover (2). Remove the rack position indicator lever. Remove the timing pin assembly. 6. Remove the rack (4) from fuel injection pump housing.7. Remove the lifter assemblies (5). Keep the lifter assemblies identified and together with their respective pumps.
Do not attempt to remove or replace the spacers in lifter assemblies (5). An improperly staked spacer can cause engine failure.
8. Remove the drive gear (6), mounting bolts and lock. 9. Remove the fuel injection pump housing bottom cover. Pull the fuel injection pump camshaft (7) out of the housing. 10. Using tool setup (B), remove the camshaft bearings.11. Remove the rack bearings using tool setup (C).12. Remove the variable timing unit bearing from the fuel injection pump housing.Assemble Fuel Injection Pump Housing
1. Using tool setup (A), install the variable timing unit bearing with the oil hole in bearing aligned with hole in fuel injection pump housing.2. Install the camshaft bearings using tool setup (C). 3. Install the rack bearings using tool setup (B). The rack front bearing should be recessed .38 in. (9,65 mm) from the front face of housing. The rack rear bearing should be installed 6.372 in. (161,8 mm) from the variable timing unit end of fuel injection pump housing. 4. Lubricate the camshaft with clean engine oil, and install it in housing. Install the fuel injection pump housing bottom cover. Install the drive gear, lock and mounting bolts.5. Install the lifter assemblies (1) in their respective positions in housing. Lubricate the rack generously with clean fuel oil, and install it in housing. If new lifter assemblies and pumps are to be installed, it will be necessary to set the fuel pump timing dimension. See FUEL PUMP TIMING DIMENSION SETTING (OFF ENGINE) in TESTING AND ADJUSTING.6. Install one of the timing pin retaining bolts, upside down, through one of the flange holes in timing pin assembly and tighten with nut. Insert the pin assembly into the timing hole in housing. Move the rack back and forth slowly until the timing pin engages slot in rack. Depress the timing pin until head of inverted bolt touches housing.
Do not attempt to install fuel injection pumps if rack is not positioned as outlined above.
7. Install rack position indicator lever (2) and cover. 8. Assemble the fuel injection pumps as follows. Lubricate all parts generously with clean fuel oil. Install the spring, washer and plunger in the body. Install the valve, spring and bonnet in body. Using wrench (D), tighten bonnet to 145 5 lb. ft. (20,05 0,7 mkg).9. Install the fuel injection pumps in their respective positions as follows: Rotate the camshaft until lifter assembly is down for the pump to be installed. Position the pump over the opening in housing. Sight down the pump and align the flat of gear with alignment pin in lifter assembly. Install the pump in housing. If the pump gear is properly aligned with alignment pin, the distance between pump body and fuel injection pump housing should be approximately 3/8 in. (10 mm) with the pump spring not compressed. Install the pump mounting bolts. 10. Install the safety shutoff control adapter housing (3).11. Remove the timing pin assembly from timing hole in fuel injection pump housing. Install the pin assembly in its storage position in housing.concluding steps: a) install variable timing unitb) install governorc) install safety shutoff and overspeed assembly (Industrial only)d) install fuel injection pump housing and governor as a unit