807664 Mercruiser PVC EMISSIONS

START BY:a) remove fuel injection linesb) remove alternator 1. Remove two nuts and washers (4) and loosen clamp (1). Remove oil breather tube (3).2. Remove the four bolts that hold guard (2) to the radiator. Remove the guard. 3. Remove nuts (5) and cover (6) from the front of the timing gear cover.4. Remove the bolt and washer that hold the fuel pump drive gear to the fuel pump. 5. Use tool (A) to loosen the drive gear from the fuel pump. 6. Disconnect governor linkage (7) from the governor.7. Disconnect two fuel lines (8) from the fuel pump.8. Put protection caps on the fuel lines and fittings. 9. Remove bolt (10) that holds drain lines (9) to the cylinder block. 10. Remove bracket (11) from the fuel injection pump housing and governor and the adapter on the cylinder block. 11. Remove three nuts (13). Remove fuel pump housing and governor (12) from the timing gear plate. 12. Remove O-ring seal (14).Install Fuel Injection Pump Housing And Governor
1. Put the number one piston in top center compression position. See FINDING TOP CENTER COMPRESSION POSITION FOR NO. 1 PISTON in TESTING AND ADJUSTING. 2. Install O-ring seal (2).3. Install drive gear bolt and washer (1) in the fuel injection pump as shown. Install tool (A) in the timing hole. Turn the camshaft with bolt (1) until tool (A) goes in the notch in the camshaft.4. Remove bolt and washer (1). 5. Install fuel injection pump housing and governor (3) on the engine. Install the three nuts that hold the fuel injection pump to the timing gear plate. 6. Install adapter (4) to the cylinder block and the fuel pump housing and governor. 7. Put fuel injection pump drive gear (5) in position and install the bolt and washer that holds it. The radiator guard and fan belts are removed for better photo illustration.8. Install tool (B) on the drive gear as shown. Put a torque of approximately 50 lb.ft. (68 N m) on the pump drive gear in a clockwise direction (as seen from the front of the engine). With the clockwise torque on the pump drive gear, tighten the bolt to a torque of 110 5 lb.ft. (149 7 N m).9. Remove tool (A). Remove the 3/8"-16 NC bolt from the flywheel.10. Turn the engine counterclockwise (as seen from rear of engine) two complete revolutions. If tool (A) goes into the notch in the camshaft of the fuel injection pump and the 3/8"-16 NC bolt goes in the flywheel at the same time, the timing is correct.11. If tool (A) can not be installed, see CHECKING TIMING BY TIMING PIN METHOD in TESTING AND ADJUSTING. 12. Remove tool (A) and install the bolt and O-ring seal.13. Connect governor linkage (6) to the governor.14. Connect two fuel lines (7) to the fuel injection pump.15. Install the clamp and bolt that hold the drain line to the cylinder block. 16. Put the gasket in position and install cover (8) and the nuts that hold it. 17. Install guard (10) and the four bolts that hold it to the radiator guard.18. Put oil breather tube (11) in position and tighten clamp (9).19. Install two nuts and washer (12).END BY:a) install fuel injection linesb) install alternator