809157 Mercruiser NUT

START BY:a. remove fuel injection pump housing and governorb. remove governor
Be careful not to cause damage to the inlet and outlet ports on the bottom of the pump housing. The pump housing must be put on wood blocks before it is disassembled.
1. Remove housing (1) and the gasket. 2. Remove the shaft and gear (2) from housing (1). 3. Remove bearing (3) from housing (1). Bearing (3) will be destroyed when it is removed. 4. Remove two bolts (4), and remove cover (5). 5. Remove bolts (9) that hold retainer (7) and gear (6) to the fuel injection pump camshaft. Remove the retainer and gear. When pinion gear (8) is removed, make a replacement of drive gear (11) with a new part.6. Remove idler gear (10). Remove drive gear (11) and pinion shaft (8). Use a soft hammer to push pinion shaft (8) out of drive gear (11). 7. Remove protective caps (14), felt washers (13) and plug (12). 8. Install tool (A) in the hole with the large diameter end without the taper down. Move the governor control to the "ON" position until the rack stops against tool (A). The racks are now in center (zero) position. Hold the rack against tool (A), and carefully remove each fuel injection pump (15) with tools (B) and (C).
When injection pumps, spacers and lifters are removed from the injection pump housing, keep the parts of each pump together so they can be installed in their original location.
9. Remove bracket assembly (16) and link (17). 10. Put identification marks on fuel racks (18) and (19), and remove the fuel racks. 11. Put identification marks on each spacer (20) and lifter (21) so they can be installed in their original position. 12. Remove fuel injection pump camshaft (22) from the pump housing.13. Remove O-ring seal (23). 14. Inspect link pivot shaft (24) and bracket locating pin (25). Make a replacement by removal of shaft (24) and dowel (25) with tool (D). 15. Inspect upper bearing (26) and the lower bearing that hold the pinion gear in the pump housing.16. Make a replacement of bearings (26) if necessary.17. Inspect idler gear shaft (27). If a replacement is necessary, remove the shaft with tooling (D). 18. Inspect fuel rack bearings (28) and camshaft bearings (29). If a replacement is necessary, remove bearings (28) and (29).19. Use tool group (E) to remove bearings (28). 20. Remove regulator valve (30). 21. Remove pin (31) to disassemble the regulator valve, and inspect the components.22. Piston (32) must move freely in valve body (30).23. Make a reference to the Specifications for spring (34).24. Make a replacement of O-ring seals (33).Assemble Fuel Injection Pump Housing
Pin (2) must not extend out of either side of valve body (3).
1. Install spring (4), piston (1) and pin (2) in valve body (3). 2. Put clean engine oil on the valve body and O-ring seals (5). Install the oil bypass valve in the pump housing. Tighten the bypass valve body to a torque of 68 14 N m (50 10 lb.ft.). 3. Install the camshaft front and rear bearings with tool group (A). Install the front bearing until it is a distance of 1.0 0.5 mm (.04 .02 in.) from the front surface of the pump housing. Install the rear bearing until it is 4.8 0.5 mm (.19 .02 in.) from the rear surface of the pump housing. Make sure both oil holes in bearing are in alignment with the oil holes in the pump housing. 4. Put tool (B) in the fuel pump housing with the dowels of tool (B) in alignment with the left fuel rack bore. Install the bolt that holds the tool in place on the housing.5. Put a new bearing in position with the tab of the bearing up. Install the bearing with tool (C) until the shoulder of tool (C) makes contact with tool (B).6. Turn tool (B), and make an alignment of the dowels on tool (B) with the right fuel rack bore.7. Do Step 3 again for the left fuel rack bearing. 8. Install shaft (6) to a height of 16.8 0.5 mm (.66 .02 in.). 9. Make sure the chamfer on the lower bearing for the pinion gear is toward the inside and the notch is in the location shown. Install the bearing 28.4 0.5 mm (1.12 .02 in.) below the bearing bore surface with tooling (D).10. Make sure the chamfer on the upper bearing for the pinion gear is toward the inside and the notch is in the location shown. Use tooling (D) to install the bearing until it is even with the upper surface of the bearing bore. 11. Install link pivot shaft (7) to a dimension of 12.19 mm (.480 in.) above the finished surface of the pump housing.12. Install bracket assembly locating pin (8) to a dimension of 4.78 mm (.188 in.) above the finished surface of the pump housing. 13. Install the pinion gear in the pump housing. Put the drive gear in position on the pinion gear shaft, and install the cover. Install tool (E) and "C" clamp as shown. Install pinion gear (9) until the drive gear makes contact with the shoulder of the pinion gear shaft. 14. Remove cover (10), and remove any metal chips or shavings that might have been caused when the drive gear was installed on the pinion shaft.15. Install idler gear (11) on the shaft.16. Install cover (10) and the two bolts that hold it in place. Turn the pump shaft while the bolts are tightened. The pump shaft must turn freely after the bolts are tightened. 17. Put clean engine oil on the camshaft bearings and camshaft (12). Install the camshaft in the pump housing.18. Install a new O-ring seal (13). 19. Install camshaft gear (14) and retainer (15) on the camshaft. 20. Install lifters (16) in their respective bores. 21. Install spacers (17) in their respective bores. If new lifters