809158 Mercruiser MOLD

START BY:a. remove automatic timing advance 1. Install tool (A) in the flywheel housing as shown. 2. Install tool (B) in the fuel pump housing, with the square end down. Use a small amount of hand force to push down on tool (B) while the fuel control lever is moved forward to the "FUEL ON" position. Rack travel will stop in the center (zero). Hold a light forward force on the governor control lever to keep the fuel rack in the center (zero position).3. Use tool (A) to turn the engine in a counterclockwise direction (as seen from the flywheel end of the engine) until a timing bolt can be installed into the flywheel. The No. 1 piston must be at top center on the compression stroke. If the hole in the flywheel is turned beyond the hole in the flywheel housing, turn the flywheel back (clockwise) a minimum of 30° beyond the hole in the flywheel before turning counterclockwise toward the hole again. This will prevent a timing error caused by play in the timing gears.4. To see if No. 1 is on the compression stroke, look at the valves of No. 1 cylinder. The valves will be closed if No. 1 cylinder is on the compression stroke. You should be able to move the rocker arms up and down with your hand. If No. 1 piston is not on the compression stroke, turn the flywheel 360°, and install the timing bolt. 5. Remove governor control linkage (4). Remove bracket assembly (8) and hose (5) from the fuel injection pump housing. Disconnect lines (6) and (7), and remove fuel transfer pump (1).6. Disconnect or remove all necessary lines, tubes and hoses from the fuel injection pump housing and fuel ratio control. Remove fuel ratio control (2). Remove all fuel injection lines (3) from the cylinder head. 7. Remove bolts (9) and bracket (10) from the left side of the fuel injection pump housing. 8. Loosen the plate (not shown) on the right head to move tube assembly (12) for more clearance to remove bolts. Remove two bolts (11) from the right side of the fuel injection housing. 9. Remove bracket (13) from the rear of the fuel injection pump housing.10. Pull the fuel injection pump housing out of the timing gear housing.11. Install two 5/16"-18 NC eyebolts in 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 unit is 50 kg (110 lb.).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
1. Remove timing bolt (1), cover (2) and plug (3). 2. Use tool (A) to turn the engine in a counterclockwise direction (as seen from the flywheel end of the engine) until timing bolt (1) can be installed into the flywheel. When the timing bolt can be turned freely in the threaded hole in the flywheel, the No. 1 piston is on top center. If the hole in the flywheel is turned beyond the hole in the flywheel housing, turn the flywheel back (clockwise) a minimum of 30° beyond the hole in the flywheel before turning counterclockwise toward the hole again. This will prevent a timing error caused by play in the timing gears. 3. To see if No. 1 piston is on the compression stroke, look at the valves of No. 1 cylinder. The valves will be closed if No. 1 cylinder is on the compression stroke. You should be able to move the rocker arms up and down with your hand.4. If No. 1 piston is not on the compression stroke, turn the flywheel 360°, and install the timing bolt. 5. Remove the plug from the front of the governor plate. Install tool (B) through the hole in the plate, and turn the fuel pump camshaft until tool (B) can be installed into the notch.
Make sure there is not paint, dirt or foreign material on the machined surface of the fuel injection pump housing and the machine surface of the cylinder block. The surface must be clean before the fuel injection pump housing is installed.
6. Inspect the two O-ring seals on the bottom of the fuel injection pump housing for wear or damage, and replace if necessary. Put 5P960 Multipurpose Type Grease on the O-ring seals to hold them in place on the bottom of the fuel injection housing over the oil inlet and outlet dowels.7. Install the O-ring seal on the front of the fuel injection pump for wear or damage, and replace if necessary. Put clean engine oil on the seal.8. Fasten a nylon strap and hoist to the fuel injection pump housing and governor, and put it in position on the engine.9. Install the bolts and the brackets that hold the fuel injection pump housing to the engine. 10. Install all fuel injection lines (5) on the cylinder head. Install fuel ratio control (4).11. Connect lines (8) and (10) to the fuel transfer pump (9).12. Connect bracket assembly (11) and hose (7) to the fuel injection pump housing.13. Install the governor control linkage (6).END BY:a. install automatic timing advance