809156 Mercruiser O-RING

START BY:a. remove fuel ratio controlb. remove governor shutoff solenoid 1. Remove the cotter pin and pin (1) that connects the linkage to the lever.2. Remove the bolt, and disconnect clip (3) that holds the fuel line to governor base.3. Disconnect wire assembly (4) from the governor plate.4. Remove the bolts and plate (2) from the governor. 5. Remove bolts (8), stop collar (7) and the spring from the governor. Plate (6) can be removed for easier access to bolt (8). Remove the bolt, cover (5) and bolt (9). 6. Install tool (A) in the fuel injection pump housing. Move governor control lever (10) until tool (A) is in place and the racks are in the center (zero) position.7. Remove bolts (11) and governor housing (12). 8. Remove the seat, one flat washer, two spring washers and spring (13).9. Disconnect fuel lines (15) from governor plate (14).10. Remove the bolts and governor plate (14) from the fuel injection pump. It is possible to remove the governor and governor plate as a unit. The above steps must be followed before the governor can be installed again in the injection pump housing.Install Governor
The drive assembly must be removed from the governor plate before the governor plate is installed for correct alignment. The drive assembly can be damaged if it is installed with the governor plate and is not in alignment with the drive pinion assembly.
1. Install a new gasket on the injection pump housing. 2. Make sure tool (A) holds the racks in the center (zero) position.3. Put governor plate (1) in position on the fuel pump housing. Make sure the dowels in governor plate (1) are in alignment with the holes in the injection pump housing. Install the bolts. 4. Install ring (2) in gear assembly (3). Make sure the dowels in gear assembly (3) are in the center of the slots in ring (2). 5. Install drive assembly (4), the spring and ring (6) in gear assembly (5) as shown. Be sure the dowels in gear assembly (3) and the holes in drive assembly (4) are in alignment.6. Use tool (B) to install ring (5) in the gear assembly. 7. Install spring (9), the spring washer, the flat washer, the spring washer and seat (7).8. Connect fuel lines (8) and wire assembly (10) to the governor plate. 9. Install a new gasket (13) and governor housing (11) on the governor plate with bolts (12).10. Remove tool (A), and install the plug. 11. Install the spring, stop collar (14) on the governor bolt with bolt (15). 12. Install a new gasket and cover assembly (16) on the governor housing. There is a strainer assembly in the cover assembly. The strainer assembly is installed with the mesh (screen) toward the governor housing. 13. Install new gaskets and plate assembly (17) and cover (19) on the governor housing.14. Connect linkage (18) on the governor lever with the pin and the cotter pin.15. Check the governor adjustment. See Governor Adjustment in Testing And Adjusting.END BY:a. install fuel ratio controlb. install governor shutoff solenoidDisassemble Governor
START BY:a. remove governor 1. Loosen the bolt, and remove lever (3) from the shaft.2. Remove strainer (2) and cover (1). 3. Bend the locks back, and remove four bolts (6) and levers (4) and (5) from the shaft. 4. Remove shaft (7) and the washer from cover (1). 5. Remove insulator (8) from the cover.6. Remove two seals (9) and bearings (10) from the cover. 7. Put a mark on low and high idle screws (11), and make a note of each turn until the idle screws are removed from the governor housing. This is done to get the approximate setting for assembly purposes. Remove the O-ring seals from the idle screws.8. Bend lock (12) down, and remove the two bolts. Remove torque spring group (13). 9. Bend the lock down, and remove bolt (15).10. Remove shaft (14) and control lever (16) from the governor housing.
To prevent possible personal injury, care must be taken when pin (17) is removed. The spring and plunger behind pin (17) are under spring force.
11. Remove pin (17), the spring and the plunger from the control lever.12. Remove band assembly (18) from the lever assembly. 13. Remove two seals (20) and bearing (19) from the governor housing. 14. Remove spring (22) from governor bolt (21).15. Remove seat (23) from riser (24).16. Remove the dowel from riser (24).17. Remove riser (24) and governor bolt (21) as a unit from governor plate (25).18. Remove governor bolt (21) from riser (24). 19. Remove spring (27) and washer (26) from the sleeve.20. Remove sleeve (28) from the servo piston valve. 21. Remove ring (32), large race (31), bearing (29) and small race (30) from sleeve (28). 22. Remove lock (34) from flyweight (33).23. Remove flyweight (33) from the governor plate. 24. Turn governor plate over, and bend locks (36) down. Remove bolts (37), bracket (35) and the servo piston assembly from the governor plate. 25. Remove dowel (43), lever (44) and servo piston assembly from bracket (35).26. Remove pin (42) and piston (38) from sleeve (40).27. Remove valve (39) from piston (38).28. Remove O-ring seal (41) from sleeve (40). 29. Hit (tap) lightly on cylinder (45) to remove it from the governor plate. 30. Remove O-ring seals (46) from cylinder (45). 31. Use tool (A) to remove retaining ring (47) from the gear assembly. 32. Remove ring (51), spring (50), drive assembly (48) and ring (49) from gear assembly (52). 33. Use tool (B) to remove ring (53) from drive gear assembly (52). Remove drive gear assembly (52) from the governor plate. 34. If dowel replacement is needed, remove dowels (55), (56) and (57) from the governor plate.35. Remove bearing (54) from the governor plate.Assemble Governor
1. If replacement of the dowels in the governor plate is necessary, see illustration for correct installation dimensions.