835001T Mercruiser PISTON ASSEMBLY

Table 1
Required Tools(1)
Tool Part Number Part Name Qty
A 9U-6198 Crankshaft Turning Tool 1
B 230-6284 Timing Pin (Camshaft) 1
C 230-6283 Timing Pin (Crankshaft) 1
D 150-3992 Timing Pin (Fuel Injection Pump) 1
E 157-3719 Ratchet Wrench 1
ZZ 9U-7067 Cap 2
9U-7069 Cap 2
(1) SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.Start By:
Remove the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley - Remove and Install".
Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install".
Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install".
Remove the air compressor, if equipped. Refer to Disassembly and Assembly, "Air Compressor - Remove and Install".
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Use the Tooling (A) to ensure that the No. 1 piston is at the top center position on the compression stroke. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston". Note: Install the Tooling (B) through the camshaft gear. Install the Tooling (C) into the crankshaft web.
Illustration 1 g00996922
Insert the Tooling (D) in the hole of fuel injection pump gear (2), through the slot in the hub and into the timing hole of the Fuel Injection Pump (X). If the Tooling (D) can be fully inserted, the fuel injection timing is correct. There should be no resistance when the Tooling (D) is inserted. Note: Do not remove the hub nut (1) from the shaft of the fuel injection pump. The hub of the fuel injection pump is installed in the correct position at the factory in order to ensure proper timing. If hub nut (1) is removed and the hub is removed, the hub will need to be accurately installed on the shaft of the fuel injection pump by the use of special equipment. Refer to your Caterpillar Dealer for more information.Note: Some Bosch VP30 fuel injection pumps do not have a locking screw. To ensure that the pump is timed correctly, refer to Systems Operation, Testing and Adjusting, "Fuel Injection Timing - Check".
Illustration 2 g00995133
Loosen the setscrew (4). Remove the spacer (5) in order to allow the setscrew (4) to tighten against the shaft of the fuel injection pump (6). Rotate the fuel injection pump gear in a counterclockwise direction in order to remove the backlash. Tighten the setscrew (4) to a torque of 31 N m (22.8 lb ft). Note: The setscrew (4) must be tightened in order to prevent the shaft of the fuel injection pump from rotating.
Remove the Tooling (D) from the body of the fuel injection pump.
Remove the four setscrews (3) and the washers from the hub of the fuel injection pump. Remove the fuel injection pump gear (2).
Illustration 3 g00994376
Disconnect the tube assembly (9). Disconnect the tube assembly (10) from the fuel injection pump.
Pull the locking mechanism in order to disconnect harness assembly (7).
Remove the nut and setscrew (13). If necessary, remove the setscrew and the bracket (12) from the cylinder block.
Remove the three setscrews (11) in order to remove the fuel injection pump.
Remove the fuel injection pump from the front housing. Remove the O-ring seal (8) from the fuel injection pump.