808740 Mercruiser PISTON/PIN (STD.) 7.4L BRAVO III

1. Disconnect hose assembly (2) from the fuel ratio control.2. Disconnect wire (1) from the wire harness.3. Remove the bolts, the nut and disconnect governor control linkage (3) from the governor shaft. 4. Remove bolts (5) and brackets (4) that hold the fuel injection pump housing to the engine. 5. Remove bolts (7) and cover (6) from the automatic timing advance housing. 6. Remove one of bolts (8) that hold the automatic timing advance to the fuel pump camshaft. 7. Install a 1/2"-13 NC guide bolt (9) in the fuel pump camshaft. This will keep retainer (10) in position so it does not fall in the automatic timing advance housing.8. Remove remaining bolts (8) from the automatic timing advance and fuel pump camshaft. The illustrations show the engine and fuel injection pump timed during removal of the fuel injection pump housing and governor. This operation does not have to be done until the fuel injection pump housing and governor is installed.9. Fasten nylon strap (11) and a hoist on fuel injection pump housing and governor (12). Carefully move the fuel injection pump and governor away from the automatic timing advance approximately 25.4 mm (1.00 in.). Remove guide bolt (9) from the camshaft but do not remove it from the automatic timing advance. Remove fuel injection pump housing and governor (12) from the engine. The weight of the unit is 59 kg (130 lb.).Install Fuel Injection Pump Housing And Governor
1. Before installation of the fuel injection pump housing and governor, make sure both the engine and the fuel pump are in correct time.
Typical Example2. Use the procedure which follows to put the No. 1 piston at top center on the compression stroke:a. Remove timing bolt (1), bolt (3), cover (4) and plug (2) from the flywheel housing.b. Use tool (A) to turn the flywheel in a counterclockwise direction (as seen from the rear of the engine).c. Install timing bolt (1) in the hole from which plug (2) was removed. When the bolt can be turned freely into the threaded hole of the flywheel, the No. 1 piston is on top center. If the hole in the flywheel is turned beyond the hole in the flywheel housing, turn the flywheel back (clockwise) a minimum of 30°. Repeat Step b again. This will prevent timing error caused by play in the timing gears.
Cylinder And Valve Locationd. Remove the left front valve cover. Look at the valves of No. 1 cylinder. The valves will be closed if No. 1 piston is on the compression stroke. You should be able to move the rocker arms up and down with your hand. If No. 1 piston is not on the compression stroke, do Steps e and f.e. Remove the timing bolt from the flywheel.f. Turn the flywheel 360° counterclockwise and install the timing bolt. If the hole in the flywheel is turned beyond the hole in the flywheel housing, turn the flywheel back (clockwise) a minimum of 30°. Repeat Step b again. This will prevent timing error caused by play in the timing gears. 3. Remove the plug from the fuel injection pump housing where tool (B) is to be installed.4. Turn camshaft (7) until tool (B) (end with taper) can be installed into the notch of the camshaft. The fuel injetion pump is in correct time.5. Inspect O-ring seal (8) for wear or damage and make a replacement if necessary. Put 5P960 Multipurpose Type Grease on the seal.6. Fasten nylon strap (5) and a hoist on fuel injection pump housing and governor (6) and put the unit in position on top of the engine. 7. Install bolts (9), finger tight only, that hold retainer (11) and the automatic timing advance to the fuel pump camshaft.8. Remove guide bolt (10) that holds retainer (11) in place. Install remaining bolt (9) (finger tight only).9. Tighten bolts (9) evenly to a torque of 34 N m (25 lb.ft.); then tighten the bolts evenly again to a torque of 68 N m (50 lb.ft.). Tighten the bolts to a final torque of 136 7 N m (100 5 lb.ft.).10. Remove tooling (B) from the fuel pump housing and the timing bolt from the flywheel. Use tool (A) and turn the engine two complete revolutions and check the timing again. 11. Install the gasket and cover (12) on the automatic timing advance housing. 12. Install bolts (14) that hold the fuel pump housing to the cylinder block. Tighten the bolts to a torque of 55 7 N m (40 5 lb.ft.).13. Put brackets (13) into position on each side of the fuel pump housing. Install the bolts into the cylinder heads first only finger tight. Install and tighten the bolts that hold brackets (13) to the fuel pump housing. Tighten the bolts that hold brackets (13) to the cylinder heads to a torque of 43 7 N m (32 5 lb.ft.). 14. Connect hose assembly (16) to the fuel ratio control.15. Connect governor control linkage (17) to the governor shaft.16. Connect wire (15) to the wire harness.END BY:a. install fuel injection lines