45592 Mercruiser NUT, WATER PUMP BODY STUDS (5/16-24)

1. Put the No. 1 piston on top center compression.2. Put the No. 1 piston at top center compression as follows: a) Turn the crankshaft clockwise (as seen from the front of the engine until a 3/8"-16 NC bolt (1) 31/2" long can be installed through the timing hole in the flywheel housing and into the hole in the flywheel. Never turn the crankshaft counterclockwise to install the bolt in the flywheel.b) Disconnect the breather from the valve cover. The rocker arms can be seen through the breather hole for No. 1 piston.c) Check to see if both rocker arms can be moved backward and forward by hand through the breather hole. The No. 1 piston is at the top center compression position when the bolt is installed in the flywheel and the rocker arms for the No. 1 piston can be moved backward and forward.d) If both rocker arms can not be moved, the No. 1 piston is not at the top center compression. Remove the bolt from the flywheel. Turn the engine clockwise as seen from the front of the engine one full turn 360° and install the bolt again.3. Disconnect fuel injection lines (1) and (2) as a unit respectively. Put protection caps on all openings in the fuel lines to keep dirt or foreign material out of the fuel system.4. Remove fuel filter (3) with tool (A).5. Disconnect governor control linkage (4). 6. Remove fuel line (5) that connects the fuel filter base to the governor. Remove oil tube (7) from the bottom of the turbocharger and the fuel injection pump.7. Disconnect air line (6) from the fuel ratio control. 8. Remove oil tube (10) that connects the engine block to the top of the turbocharger as a unit. Disconnect fuel pump overflow tube (9) and fuel pressure sensing line (8). 9. Remove the nuts that hold the timing gear plate and remove timing gear plate (11). 10. Loosen center line bolt (12), that holds the fuel injection pump drive gear to the fuel injection pump camshaft until the washer is approximately 1/8 in. (3.2 mm) away from the drive gear. Do not remove the bolt at this time.11. Install tooling (B) on the drive gear. Tighten the center bolt in tooling (B) until the drive gear is loose. Remove tooling (B), bolt (12) and the washer. The drive gear will stay in the timing gear cover.12. Remove the nuts that hold the fuel injection pump housing and governor to the timing gear cover and remove fuel injection pump housing and governor (13) as a unit.Install Fuel Injection Pump Housing And Governor
1. Put the No. 1 piston at the top center compression position before the fuel injection pump housing and governor is installed on the engine with the following procedure. a) Put fuel injection pump housing and governor (1) in position on the machine and install washer and bolt finger tight. b) Install timing pin (2) in hole in the rear of torque spring cover.c) Turn the crankshaft in the direction of engine rotation and install the timing bolt in the flywheel. Never turn the crankshaft backward to install the bolt in the flywheel. The No. 1 piston is at the top center compression position when the bolt is installed in the flywheel, and both rocker arms for the No. 1 piston can be moved backward and forward.2. With the timing bolt and pin in position, put 50 lb.ft. (70 N m) torque on drive gear in the clockwise direction (as seen from the front of the engine). With the 50 lb.ft. (70 N m) torque in application on the drive gear, tighten the drive bolt to a torque of 110 5 lb.ft. (149 7 N m). Remove the timing bolt and pin. 3. Install cover (3) for the timing gear. Tighten the nuts that hold the cover to a torque of 20 5 lb.ft. (25 7 N m). 4. Install bracket (4) and tube that makes a connection from the turbocharger to the engine. 5. Install oil tube (6) that connects to the fuel injection pump and to the bottom of the turbocharger. Install the fuel line that connects the fuel filter base to the governor and air line (7) that connects to the fuel ratio control. 6. Connect fuel pressure sensing line (9) and fuel pump overflow tube (11).7. Remove the protection caps and the plugs. Connect fuel lines (8) and (10) as a unit respectively. Tighten the nuts for the fuel lines to a torque of 30 5 lb.ft. (40 7 N m) with tool (B).8. Connect governor control linkage (12) with a pin and a cotter pin.9. Install the fuel filter with tool (A).