808201 Mercruiser OIL PUMP W/GEAR

start by: a) remove accessory drive 1. Remove nut (1) and the lock from the shaft.2. Install the nut back on the shaft until it is even with the end of the shaft. 3. Install tooling (A) on drive gear (2) as shown. Remove the drive gear with tooling (A). Remove the nut and the drive gear from the shaft. 4. Remove water lines (3) and (5) from the engine.5. Remove fuel filters and base (6) as a unit from the engine.6. Remove clamp (4) for the fuel injection lines. Disconnect the fuel injection lines from the fuel injection pumps.
Put covers over the openings to prevent dirt and foreign material from getting into the fuel system.
7. Disconnect fuel lines (7) from the fuel transfer pump.8. Install a 3/8"-16NC forged eyebolt in the top of the fuel transfer pump adapter housing. Fasten tool (B) to a hoist and to the eyebolt. Fasten lift straps to the fuel system and to the hoist. 9. Remove four bolts (8) and locks that hold the fuel system to the timing gear housing assembly. 10. Remove two bolts (9) from the fuel transfer pump adapter housing. 11. Remove tube (10) from the cylinder block. 12. Remove fuel system (11) from the timing gear housing assembly. Weight of the fuel system is 350 lb. (159 kg). 13. Remove tube assembly (12) from the timing gear housing assembly.14. Remove three bolts (14) and the locks. Remove thrust washer (13) and the washer from the timing gear housing assembly. 15. Remove the nuts and locks that hold shaft (15) in position. Remove the shaft from he timing gear housing assembly.16. Fasten a hoist to the timing gear housing assembly. 17. Remove the thirteen bolts that hold the timing gear housing assembly in position. Remove timing gear housing (16). Weight of the timing gear housing is 136 lb. (61.7 kg). 18. Remove three nuts (17). Remove bracket (18). 19. Remove cover (19) from the timing gear housing assembly. 20. Remove bearing (20) and two bearings (21) from the timing gear housing assembly.Install Timing Gear Housing Assembly
1. Install two bearings in the timing gear housing assembly with tooling (A). Install the bearings until they are even with the outside and inside surfaces of the timing gear housing assembly.2. Install bearing (1) in the timing gear housing with tooling (B). Install the bearing until it is even with the inside surface of the timing gear housing assembly. 3. Put cover (3) and bracket (2) in position on the timing gear housing assembly. Install the three nuts that hold them. 4. Fasten a hoist to the timing gear housing assembly. Put the timing gear housing assembly (4) in position on the cylinder block. Install the thirteen bolts that hold it.5. Install seal (5) on the shaft. 6. Put shaft (6) in position on the timing gear housing assembly with the oil holes in the shaft in a down position. Install the nuts and locks that hold the shaft in position. 7. Put washer (7) and thrust washer (8) in position on the timing gear housing assembly. Install the locks and bolts that hold them. 8. Install tube assembly (9) on the timing gear housing assembly. 9. Fasten tool (C) and a hoist to the fuel system as shown. Put fuel system (10) in position in the timing gear housing assembly. 10. Install two bolts (11) in the fuel transfer pump adapter housing. 11. Install four bolts (12) and locks.12. Remove the hoist and tool (C) from the fuel system. 13. Connect the fuel injection lines (13) to the fuel injection pumps. Tighten the fuel injection lines to a torque of 30 5 lb.ft. (40.7 6.8 N m).14. Install clamp (14).15. Install tube (16).16. Connect fuel lines (15) to the fuel transfer pump. 17. Install fuel filters and base (19).18. Install water tubes (17) and (18). 19. Heat drive gear (20) to a maximum temperature of 450°F (232°C). Install the drive gear on the shaft. Install the lock and nut (21). Tighten the nut to a torque of 325 25 lb. ft. (440.6 33.9 N m).20. Check the end play of the shaft in the fuel pump and governor drive housing with tool (D). The end play must be .008 to .012 in. (0.2 to 0.3 mm).end by: a) install accessory drive