808298 Mercruiser PLUG

Install Spring As Shown If the spring keeps the pressure in the fuel injection pump housing above 25 psi (170 kPa) with the engine operating under full load, the spring is good.Pressure of fuel in housing for fuel injection pumps, (Full Load) ... 30 5 psi(205 35 kPa). Install guide pin (A) to depth (B) [.642 .003 in. (16.31 0.08 mm)]. Slot in guide pin (A) must be in area shown from center of lifter.(7) Torque for bushing ... 70 5 lb. ft.(95 7 N m)(8) 4N4318 Spring for injection pump:Length under test force ... 1.35 in.(34.3 mm)Test force ... 12.5 1.3 lb.(55.5 5.8 N)Free length after test ... 1.566 in.(39.78 mm)Outside diameter ... .728 in.(18.49 mm)(9) Torque for bolt holding sleeve on control shaft ... 24 2 lb. in.(2.8 0.2 N m)(10) Torque for the nuts that hold the fuel lines (Use 5P144 Fuel Line Socket) ... 30 5 lb. ft.(40 7 N m)(11) Torque for the nuts that hold the nozzles ... 105 5 lb. ft.(142 7 N)(12) Body.(13) Put 5P3931 Anti-Seize Compound on threads of glow plug and tighten to ... 120 24 lb. in.(13.6 2.8 N m)(14) Tighten nozzle finger tight on body.(15) Torque for precombustion chamber (put 5P3931 Anti-Seize Compound on threads) ... 150 10 lb. ft.(205 14 N m) See Glow Plug Positioning.
Typical Illustration (16) Torque for bolts holding clamps on fuel injection lines:With rubber damper ... 84 24 lb. in.(9.6 2.8 N m)Without damper ... 108 36 lb. in.(12.2 4.1 N m)(17) Lever assembly.(18) Clearance between lever assembly (17) and governor housing when shaft assembly (19) is pulled against the governor housing ... .437 in.(11.10 mm)(20) Spring for the terminal shaft. Install the spring (20) for the terminal shaft so that the end of the spring is in the 30° range as shown.9S8597 Spring for terminal shaft:Color code (stripes) ... 1 whiteLength under test force ... .584 in.(14.83 mm)Test force ... 56.3 lb.(251 N)Free length after test ... 1.21 in.(30.7 mm)Outside diameter ... 1.635 in.(41.53 mm)Diameter of wire ... .135 in.(3.43 mm)2P726 Spring for terminal shaft:Color code (stripes) ... 1 redLength under test force ... .584 in.(14.83 mm)Test force ... 109 lb.(485 N)Free length after test ... 1.04 in.(26.4 mm)Outside diameter ... 1.635 in.(41.53 mm)Diameter of wire ... .156 in.(3.96 mm)4N4366 Spring for terminal shaft:Length under test force ... .584 in.(14.83 mm)Test force ... 156 lb.(692 N)Free length after test ... 1.016 in.(25.81 mm)Outside diameter ... 1.638 in.(41.61 mm)Diameter of wire ... .168 in.(4.27 mm)9L6508 Spring for terminal shaft:Color code (stripes) ... 1 yellowPut a load on spring of ... 5.00 lb.(22.2 N)Then make spring shorter by ... .700 in.(17.78 mm)Total test force ... 19.70 .52 lb.(87.63 2.31 N)Free length after test ... 1.74 .02 in.(44.2 0.5 mm)Outside diameter ... 1.518 in.(38.56 mm) (21) 9S8632 Low Idle Spring:Length under test force ... 1.20 in.(30.5 mm)Test force ... 40 4 lb. ft.(180 18 N)Free length after test ... 2.00 in.(50.8 mm)Outside diameter ... .880 in.(22.35 mm)