808542 Mercruiser LOCKWASHER

1. Remove the bolts and the plate from the side of the fuel injection pump housing.2. Install tool (A) in the fuel injection pump housing. Move the rack until tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to remove the fuel injection pumps.3. Use tool (B) to remove bushing (1) from the fuel injection pump housing.4. Remove the O-ring seal from the fuel injection pump housing. 5. Install tool (C) on the bonnet, and remove the fuel injection pump. Spacers (2) are the same thickness for each fuel injection pump so they can be mixed. The fuel injection pump plungers and barrels are sets and can not be mixed.6. Remove spacer (2) from the fuel injection pump housing.7. Do Steps 3 through 6 to remove the other fuel injection pumps.Install Fuel Injection Pumps
1. Install spacer (1) in the fuel injection pump housing. 2. Install tool (A) in the fuel injection pump housing. Move the rack until tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to install the fuel injection pumps.3. Turn the camshaft until the lobe of the camshaft is down for the pump to be installed.4. Install tool (B) on the bonnet of the fuel injection pump.5. Install the fuel injection pump in the pump housing with saw cut (slot) (3) in the gear in alignment with the small pin (2) and groove (4) in the barrel in alignment with dowel (5) in the pump housing. 6. Put clean oil on O-ring seal (6), and install it in the fuel injection pump housing.7. Install the bushing by hand until it is even with the top of the housing. If the bushing can not be installed this far by hand, remove it. Remove the fuel injection pump, and put the pump in alignment again, and install the bushing again. 8. Install tool (C) on the bushing and tighten the bushing to a torque of 190 10 lb. ft.). 9. Install tooling (D) to measure total rack travel. Correct rack travel is 15.7 mm (.618 in.). A smaller measurement is an indication of incorrect fuel injection pump installation.10. Do Steps 1 through 9 again for installation of the other fuel pumps.11. Install the cover and gasket on the fuel injection pump housing.END BY:a. install governorDisassemble Fuel Injection Pumps
START BY:a. remove fuel injection pumps
Be careful when the injection pumps are disassembled. Do not damage the surfaces of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. 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.
1. Pull plunger (4) and washer (3) out of barrel (1) and spring (2).2. Remove spring (2) from barrel (1). Do not remove the gear from the plunger. The gear and plunger are assembled and adjusted at the factory. 3. Use the following procedure to put the fuel pump in position on tooling (A).a. Select the correct turret position.b. Place a barrel assembly into the turret.c. Loosen the nut on the clamp.d. Adjust clamp end (6) until the bonnet is almost touching the barrel when the clamp handle is in the locked position.e. Tighten the nut on the clamp.4. Use tool (B) to expand ring (5), and carefully lift it off the fuel pump.5. Slowly release the clamp handle of tooling (A), and remove the lockring.6. Remove bonnet (7), spring (8) and valve (9) from barrel (1).Assemble Fuel Injection Pumps
Put clean fuel oil on all parts during assembly.
1. Put spring (2) and valve (5) in barrel (1).2. Put bonnet (4), barrel (1) and ring (3) in position on tool (A). 3. Put the barrel assembly in position on tooling (A). Lower the handle on tool group (A) to hold the fuel pump together.4. Use tool (B), and lower ring (3) on to the barrel and the bonnet to hold them together.5. Remove the barrel assembly from tooling (B). 6. Install spring (7) on barrel (4).7. Install washer (8) on plunger (9). Make sure the spring seat on the washer is away from the gear on the plunger.8. Install plunger (9) in barrel (4). Make sure spring (7) is engaged in the spring seat on washer (8).END BY:a. install fuel injection pumps