5442100NP Mercruiser STERNDRIVE UNIT, Complete

1. Put the fuel injection pump housing and governor in position on Tool (A).2. Remove bolt (3) to disconnect the lever and link.3. Remove bolts (2) and remove control linkage (1) from the governor shaft. 4. Remove bolts (4) and plate (5). 5. Remove cover assembly (6), plate (9), and shutoff solenoid (7) from rear governor housing (8).6. Remove the bolts, rear governor housing (8) and gasket from the front governor housing. 7. Remove the governor spring (10) and seat from the guide in the rear governor housing.8. Remove bolt (11) that holds lever assembly (12) to the shaft. There is a key in the (slot) groove of the shaft assembly that must be removed before the shaft assembly is removed from the rear governor housing.9. Remove shaft (13), lever (12), lever (14) and the spacer from the rear governor housing. 10. Remove plug (16) and lip seal (15) from the housing. Spacers (17) and (19) are different sizes. Make sure they are assembled in the correct position.11. Use needle nose pliers, and remove the shaft. Remove spacer (17), lever (18) and spacer (19) from the governor housing. 12. Remove two setscrews and locknuts (20) if necessary. 13. Release spring (21) from the notch in the housing. Remove snap ring (22), and remove shaft (23) from the housing. Remove lever (24) and spring (21). 14. Remove lip seal (25) from the housing. 15. If necessary, remove the screws, cover (26) and the gasket from the governor housing. 16. Remove high idle cover (27) and three O-ring seals (28). 17. Remove lip seal (30), dashpot valve (31), fitting (29), insulator and high idle adjustment (32) from the rear housing. 18. Remove two bolts (33), housing (34) and the gasket from the fuel pump housing. 19. Remove bolts (35), and remove torque control group (36) from the block.
Depending on the different engine applications, torque control groups will vary. Inspect all parts for wear and damage, and make a note of the correct sequence of the parts for assembly purposes.
For additional information, see the Specifications Manual. 20. Remove the bolts and block (37) for the full load stop from the housing. 21. Remove the bolt that holds collar (39) to bolt (40).22. Remove collar (39) and spring (38) from bolt (40). Remove bolt (40) from the block.23. If necessary, remove the stop screw and the power setting screw from collar (39). It may be necessary to turn the piston to remove the servo from the rack.24. Remove the three bolts and governor servo (41) from the fuel injection pump housing. 25. Remove lockring (47), seat (46), spring (45) and sleeve (44) from valve (43). Remove lockring (42) from the groove in the center of valve (43). 26. Remove sleeve (48), valve (49) and piston (50) from the governor servo. Remove O-ring seal (54) from sleeve (48). Remove pin (51) and lever (52) from cylinder (53). 27. Use Tool (C) to hold spring (55) under compression so the ring on the governor shaft can be removed.28. Remove the ring, and carefully remove Tool (C).29. Remove bearing (56) the sleeve and spring (55) from the governor shaft. 30. Remove ring (57) and dashpot assembly (58) from the governor shaft. 31. Use Tool (B), and remove ring (64) from seat (61).32. Remove ring (63) and spool (62) from seat (61).33. Remove seat (61) and spring (60) from shield (59). 34. Remove over fueling spring (66), if equipped, and riser (65) from the governor shaft. Later models do not use over fueling spring (66). 35. Remove ring (67), races (68) and bearing (69) from the riser. 36. Remove the bolts and carrier assembly (70) from the fuel injection pump housing. 37. Remove dowels (72) and flyweights (73) from the carrier assembly.38. Remove dowel (71) from the governor shaft, and remove the governor shaft from the carrier assembly. 39. Remove races (74) and (76) and bearing (75) from the camshaft in the fuel injection pump housing.Assemble Governor
1. Put the fuel injection pump housing in position on Tool (A). Install race (76) bearing (75) and race (74) on the end of the camshaft in the fuel injection pump housing. 2. Put flyweights (73) in position on carrier assembly (70), and install dowels (72) to hold the flyweights in place. The flyweights must move freely on the dowels and have 0.010 to 0.230 mm (.0004 to .0090 in) end play. 3. Install governor shaft (77) on carrier assembly (70). 4. Install dowel (71) in governor shaft (77) and slide carrier assembly (70) down on the governor shaft until dowel (71) fits into the slot in the carrier assembly.5. Install carrier assembly (70) on the end of the camshaft. 6. Install race (68), bearing (69), race (68) and ring (67) on riser (65). 7. Install riser (65) and over fueling spring (66), if equipped, on the governor shaft. 8. Install spool (62) and ring (63) on seat (61) and use Tool (B) to install ring (64) to hold them in position.9. Install seat (61) on spring (60). Install spring (60) on shield (59). 10. Install dashpot assembly (58) on the governor shaft. 11. Install ring (57) in the groove on the governor shaft. Install sleeve (78), spring (55), the sleeve and bearing (56) on the governor shaft. 12. Use Tool (C) to hold spring (55) under compression, and install the ring in the groove on the governor shaft. 13. Put lever (52) in position on governor servo (53), and install pin (51) to hold the lever in place. Use a hammer and chisel to move the metal (stake) four places 90 degrees apart on the outside surface on both legs of the governor servo to hold pin (51) in place.14