816785 Mercruiser MANIFOLD STRIP (FRONT)

Start By:a. remove electric starting motor 1. Remove six screws (1) and the lockwashers that hold cover (2) in position. Remove the cover.2. Use tool (A) to remove fuel filter (3). 3. Mark the location of the governor control lever in relation to the shaft. Disconnect governor linkage (5).4. Remove two bolts (6) and the washers that hold housing (4) in position. Remove the housing. 5. Put identification on two wires (10) that are connected to the fuel shut-off solenoid. Disconnect the two wires.6. Disconnect tube assembly (9) from air fuel ratio control (7).7. Disconnect two tube assemblies (13) from the fuel transfer pump and the fuel filter base.8. Disconnect tube assembly (12) from the fuel injection pump housing. Remove clip (11) from the fuel injection pump housing.
Two wrenches must be used when the fuel injection lines are loosened to prevent damage to the nozzles.
9. Remove six fuel injection lines (8). Put protective caps in the fuel injection lines and on the fuel injection pumps to keep dirt and debris out of the fuel system. The bolts used to hold the electric starting motor to the flywheel housing can be used to hold tool (B) in position.10. Install tool (B) in the flywheel housing at the location for the electric starting motor.11. Remove timing pin plug (14) from the flywheel housing.12. Use the following procedure to put the No. 1 piston at top center on the compression stroke. No. 1 piston, at top center (TC) on the compression stroke, is the starting point for all timing procedures:
The engine is viewed from the flywheel end when the direction of rotation is given. Do not turn the flywheel backwards.
a. Using tool (B), rotate the flywheel counterclockwise until tool (C) can be installed through the opening in the flywheel housing and into a hole in the flywheel. Do not turn the flywheel backwards. b. Remove bolt (15) and breather assembly (16) from the valve cover. By looking through the breather hole in the valve cover, check to see if both rocker arms for the No. 1 piston are loose and can be moved backward and forward by hand. If both rocker arms do not move, then the No. 1 piston is not at top center of the compression stroke.c. If the No. 1 piston is not at top center of the compression stroke, remove tool (C) from the flywheel. Using tool (B), rotate the flywheel counterclockwise 360°. Reinstall tool (C) into the hole in the flywheel. Check to see if both rocker arms for the No. 1 piston are loose and can be move backward and forward by hand. If free movement is felt, the No. 1 piston is at top center of the compression stroke. 13. Remove four bolts (17), cover (19) and the gasket from the side of the fuel injection pump housing.14. Remove six nuts (20), the washers, cover (18) and the gasket from the front housing. 15. With cover (19) removed, install tool (C) into the groove of the injection pump camshaft.16. Remove bolt (21) and the washer that hold fuel pump drive gear (22) in position. 17. Install tool (D) as shown, and loosen fuel pump drive gear (22) from the end of the camshaft. 18. Fasten a lifting sling and a hoist to fuel injection pump housing and governor (23) as shown.19. Remove two bolts (24) and the washers that hold the fuel injection pump housing and governor to the oil manifold.
Be sure tool (C) stays in the groove of the camshaft when the fuel system is removed from the machine.
20. Remove three nuts (25) and the washers that hold the fuel injection pump housing and governor to the timing gear plate. Remove fuel injection pump housing and governor (23). The weight of the fuel injection pump housing and governor is 27 kg (60 lb). The following steps are for the installation of the fuel injection pump housing and governor.21. Check the condition of the two o-ring seals used on the front of the fuel injection pump housing. If the seals are worn or damaged, use new parts fro replacement. Install the o-ring seals on the fuel injection pump housing. Put clean engine oil on the o-ring seals. 22. Fasten a lifting sling and a hoist to fuel injection pump housing and governor (23) as shown. Put the fuel system in position on the three stud in the timing gear plate. Install the three washers and nuts (25) which hold it.23. Install the two washers and bolts (24) that hold the fuel system to the oil manifold.
After the fuel injection pump housing and governor are installed on the timing gear plate, be sure the rack is free to move. It is possible for the o-ring seal on the drive end of the fuel injection pump housing to hold the rack and prevent free movement. If the rack does not move freely, remove the fuel injection pump housing and governor, and check the o-ring seal on the drive end of the fuel injection pump housing.
24. Put fuel pump drive gear (22) in position on the end of the camshaft. Install bolt (21) and the washer to hold the drive gear in place. Install the washer with the larger outside diameter toward the head of bolt (21). Tighten bolt (21) only finger tight.25. Install two nuts of the appropriate size on one of the outside mounting stud for cover (18). Put a piece of round stock in one of the lightening holes in the fuel pump drive gear. Using a pry bar, put a force of approximately 68 N m (50 lb ft) on the fuel pump drive gear in a clockwise direction (as