806210 Mercruiser LOCKWASHER, (.437), External Tooth

start by:a) remove fuel ratio controlb) remove fuel injection linesc) remove fuel transfer pump1. Lift the hoods and hold them in place with the hood locks.2. Put the fuel injection pump in correct timing with the engine as follows: a) Remove plug (4) from the governor plate. Turn the engine with tool (B) to put No. 1 piston at top center compression stroke.b) Install tool (A) in the opening in the governor plate to engage with the timing groove in the fuel injection pump camshaft. See FINDING TOP CENTER COMPRESSION POSITION FOR No. 1 PISTON AND CAMSHAFT TIMING FOR THE FUEL INJECTION PUMP in TESTING AND ADJUSTING.3. Disconnect fuel lines (2) from the governor plate. Remove clip (3) and bolt that fastens line to governor plate.4. Remove nut and bolt (1) to disconnect linkage rod from lever. 5. Remove the vee belt set from the fan drive and disconnect the spring (6) from the belt tightener.6. Remove the gasket and covers (5) and (7) from the automatic timing advance housing.
Do not let the retainer drop into the housing.
7. Remove the four bolts and retainer (8) that hold the automatic timing advance to the fuel pump camshaft. 8. Remove tube (9) from housing assembly.9. Remove bolts (10) and brackets (11) from each side of the fuel injection pump housing.10. Pull the fuel injection pump housing out of the timing gear housing. 11. Install a 3/8"-16 NC forged eyebolt on the front and a 5/16"-18 NC on the rear of the fuel injection pump housing. Fasten a hoist to the fuel injection pump housing and governor and remove it from the engine. Weight of the fuel injection pump housing and governor is 130 lb. (59 kg).12. Inspect the O-ring seals on the bottom and the seal on the front of the fuel injection pump housing. If the seals have damage, use new parts for replacement.
Do not cause damage to the oil inlet and outlet dowels on the bottom of the fuel injection pump housing.
Install Fuel Injection Pump Housing And Governor
Make sure there is no paint, dirt or foreign material on the machined surface of the fuel injection pump housing and the machined surface of the cylinder block. The surface must be clean before the fuel injection pump housing is installed.
1. Put 5P960 Multipurpose Type Grease on the two O-ring seals to hold them in place. Install the two seals on the bottom of the fuel injection housing over the inlet and outlet dowels. Install O-ring seal (1) on the front of the housing. Put a small amount of clean engine oil on the seal.2. Turn the fuel injection pump camshaft until tool (A) can be installed in the groove of the fuel injection pump camshaft.3. Fasten a hoist to the fuel injection pump housing and governor. Put the unit in position on the engine. Make sure the fuel injection pump housing is in the automatic timing advance unit and the bolt holes in the fuel injection pump housing are in alignment with the bolt holes in the engine. 4. Install the bolts (2) and brackets (4) that hold the unit in position.5. Install the rubber hose on housing assembly at location (3). Make sure the automatic timing advance unit is in correct position on the fuel injection pump camshaft.6. Install the retainer and the bolts that hold the automatic timing advance unit on the fuel pump camshaft. Tighten the bolts to a torque of 20 lb.ft. (25 N m) with the timing pin in the fuel pump camshaft.7. Remove the timing pin and tighten the bolts to a torque of 100 5 lb.ft. (135 7 N m). Install timing pin (A) after the bolts are tightened to make sure everything is in correct alignment.8. Remove tool (A) and install the plug. 9. Install the gasket and covers (5) and (6) on automatic timing advance housing. 10. Connect spring (7) to the belt tightener.11. Install vee belts (8) on the fan drive and belt tightener. 12. Connect the governor control linkage (9) to lever.13. Install fuel line clip (10) and three fuel line hoses to the governor plate.end by:a) install fuel transfer pumpb) install fuel injection linesc) install fuel ratio control