806591 Mercruiser STUD

Start By:a. remove fuel linesb. remove fuel filter base 1. Remove nuts (2) and cover (1) from the timing gear cover. 2. Loosen bolt (3). Leave a gap of 3.2 mm (.125 in.) between the washer and the gear. 3. Use tool (A) to remove gear (4). 4. Remove the nut and disconnect cable assembly (5) from the governor control lever.5. Remove the bolts and disconnect bracket assembly (6) from the governor. 6. Disconnect pressure line (7) at the fuel ratio control.7. Put a mark on wires (9) and disconnect them from the fuel shutoff solenoid.8. Disconnect wires (8) from the alternator. 9. Remove clamps (11) and tube assemblies (10) and (12) from the engine. 10. Remove the bolt and disconnect clip (16).11. Disconnect tube assemblies (13) and (14) and hose (15). 12. Remove bolts (18) and nuts (17) that hold the fuel injection pump and governor in place. 13. Remove nut (19), the bolt (other side not shown) and heat shield (20) from the engine. 14. Fasten a strap and hoist to fuel injection pump housing and governor (21) as shown.15. Pull drain line (22) from the clip on the engine block.16. Remove fuel injection pump housing and governor (21). The weight of the fuel injection pump housing and governor is approximately 26 Kg (58 lb.).Install Fuel Injection Pump Housing And Governor (Earlier)
1. Put O-ring seals (23) and (24) in position on the fuel injection pump housing and governor. Put clean oil on the O-ring seals. 2. Put the fuel injection pump housing and governor in position on the oil manifold and the timing gear plate with bolts (18) and nuts (17).3. Put drain line (22) into position on the clip on the engine block.
After the fuel injection pump housing and governor are installed on the timing gear plate, be sure the rack is free to move. The O-ring seal (23) on the drive end of the fuel injection pump can hold the rack and prevent free movement of the rack. If the rack does not move freely, remove the fuel injection pump housing and governor and check the O-ring seal on the drive end of the fuel injection pump housing.
4. Install heat shield (20) between the manifold and fuel injection pump housing and governor. Tighten the bolt to a torque of 23 4 N m (17 3 lb.ft.).5. Connect tube assemblies (13) and (14) and hose assembly (15) as shown.6. Install bolt and clip (16). 7. Install tube assemblies (10) and (12) to the engine and clip (11) that holds them together. 8. Connect wire assemblies (8) to the alternator.9. Connect wires (9) to the fuel shutoff solenoid.10. Connect pressure line (7) to the fuel ratio control. 11. Connect bracket (6) to the governor.12. Connect cable assembly (5) to the governor control lever. 13. Use the following procedure to put the No. 1 piston at top center on the compression stroke. No. 1 piston at top center (TC) on the compression stroke is the starting point for all timing procedures.a. Loosen hose clamps (26), bolt (25) and remove the breather from the valve cover. b. Remove the plug from the flywheel housing.c. Turn the crankshaft clockwise (as seen from the front of the engine) until a 3/8"-16 NC bolt (27) at least 2.5 in. long can be installed in the flywheel through the hole in the flywheel housing. Do not turn the crankshaft counterclockwise. The rocker arms for No. 1 piston can be seen through the breather hole in the valve cover.d. Check to see if both rocker arms for the No. 1 piston can be moved backward and forward by hand. The No. 1 piston is at top center on the compression stroke when bolt (27) can be put in the flywheel through the hole in the flywheel housing, and both rocker arms for the No. 1 piston can be moved backward and forward by hand.e. If both rocker arms can not be moved by hand, the No. 1 piston is not at top center on the compression stroke. Remove bolt (27) from the flywheel and turn the crankshaft clockwise one full turn (360°). Install the timing bolt in the flywheel again. Check to see if both rocker arms for the No. 1 piston can be moved backward and forward by hand. 14. Remove the bolts and cover (28) from the fuel pump housing. 15. Install the gear and bolt (3) on the fuel injection pump camshaft without the washer. 16. Install tooling (A) in the fuel injection pump housing. Push on tool (A) and turn the fuel injection pump camshaft. When tooling (A) slides down into the groove (slot) in the fuel injection pump camshaft, the fuel injection pump is in the No. 1 piston top center position.17. With tool (A) still in position remove the bolt from fuel injection pump camshaft.18. Install the washer and the bolt in the fuel injection pump camshaft. Make sure the washer is installed with the large outside diameter toward the bolt head. Tighten the bolt finger tight only. 19. Install tool (B) on the gear.20. Use two torque wrenches to put a clockwise force of 68 N m (50 lb.ft.) on tool (B) to remove the gear clearance (backlash) while the bolt is tightened to a torque of 270 25 N m (199 18 lb.ft.).21. Check the timing as follows to make sure it is correct:a. Remove the timing pin from the pump camshaft and the bolt from the flywheel.b. Turn the crankshaft clockwise (as seen from the front of the engine) approximately 1/2 turn. Install the timing pin again.c. While the crankshaft is turned clockwise (as seen from the front of the engine), push on the timing pin (A) until it slides into the groove (slot) in the pump camshaft.d. Install the bolt in the flywheel. The timing is correct when the bolt is installed in the flywheel and the timing pin (A) is installed in the groove (slot) in the pump