823728 Mercruiser OVERHAUL KIT

1. Remove tachometer drive adapter (1) and the washer from the fuel injection pump camshaft. 2. Use tooling (A) to remove gear (2) from the fuel injection pump camshaft. 3. Remove screw (3), the washer and gear (4) from the camshaft. 4. Use tooling (B) to remove gear (5) from the camshaft.Install Camshaft Gears
Do not heat the gear for the camshaft with a torch or to a temperature of more than 315°C (600°F). Higher temperatures can cause the dowels to loosen and come out of the gear. Do not use force to install the gear. Damage to the camshaft or camshaft thrust pin can be the result.
1. Heat large gear (1) for the camshaft to a maximum temperature of 316°C (600°F). Put the groove (slot) on the gear in alignment with the dowel on the camshaft and install the gear. 2. Put gear (2) in position on the dowels in the large camshaft gear. Install washer (3) with the pin in the washer in alignment with the hole in the camshaft. Install the screw to hold washer (3) and the gear in place. Tighten the screw to a torque of 7.9 0.6 N m (68 5 lb.in.). 3. Use a hammer and punch to move the metal (stake) on the screw so it will not loosen. 4. Install bolt (4) and the washer on the fuel injection pump camshaft. Remove the plug from the fuel injection pump housing and install timing pin (A). Turn the fuel injection pump camshaft clockwise as seen from the front of the engine. While the camshaft is turned push on timing pin (A) until it slides into the groove (slot) in the fuel injection pump camshaft. Remove bolt (4) and the washer. 5. Install drive gear (5), washer (6) and tachometer drive adapter (7) in the fuel injection pump camshaft but do not tighten adapter (7).6. Install the timing gear cover and oil pump. See TIMING GEAR COVER AND OIL PUMP installation.7. Adjust the fuel injection timing as follows: a) Remove the cap and fitting from the timing hole in the timing gear cover and install a 5/16"-18 NC bolt (9) 2 1/2 in. long. The cover bolt from hole (8) can be used. Turn the crankshaft clockwise until bolt (9) can be installed into the camshaft gear and is in the center of the timing hole. The engine is now in the correct time with the fuel injection pump.b) With timing pin (A) in the fuel injection pump camshaft and bolt (9) in the engine camshaft gear, tighten tachometer drive adapter (7) to a torque of 149 14 N m (108 10 lb.ft.).c) Remove timing pin (A) and bolt (9).8. Check the fuel injection timing as follows: a) Turn the crankshaft clockwise as seen from the front of the engine 1 1/2 turns. Install timing pin (A) in the fuel injection pump housing. While the engine is turned another 1/2 turn, push on timing pin (A) until it slides into the groove (slot) in the fuel injection pump camshaft. Install bolt (9) in the engine camshaft gear. The fuel injection timing is correct if both timing pin (A) and bolt (9) can be installed.b) If bolt (9) cannot be installed, the gear must be loosened on the fuel injection pump camshaft and the timing procedure must be done again.c) When the timing is correct, remove timing pin (A) and bolt (9). Install the plug in the fuel injection pump housing. Install the fitting and cap in the timing gear cover. Install the tachometer adapter on the timing gear cover.