806235A 1 Mercruiser THERMOSTAT HOUSING ASSEMBLY

1. Remove seven bolts (1), two bolts (2), housing (3) and the gasket. 2. Remove governor spring (4), the two wave washers, one flat washer and seat from the guide in the housing. 3. Remove the bolts, cover assembly (5) and the gasket. 4. Use tooling (A) to remove seal (6) from cover (5). 5. Remove low idle adjustment screw (8) and spring (7) from the housing. 6. Remove shaft assembly (10), lever (9) and lever (11) from the housing. 7. Remove two snap rings from pins (13), and remove pins (13). Remove plates (12) and stop (14) from the shaft assembly. 8. Remove pin (16), pin (15) and spring (17) from the shaft assembly. 9. Remove shaft (18) and lever (19) from the housing.
Remove check valve (20) only if a replacement is necessary, because the check valve will be damaged during the removal.
10. Remove check valve (20) if a replacement is necessary. 11. Remove contact (21) and body (22) for the governor dashpot adjustment screw from the housing. Remove bolts (23), cover (24) and the gasket from the housing. 12. Remove seal (25) and adjustment screw (26) for high idle. 13. Remove two bolts (27), housing (28) and the gasket from the fuel injection pump housing. 14. Remove bolts (29) and torque control group (30).15. Disassemble the torque control group and inspect the spacer, spring and insulator for damage or wear. 16. Remove bolts (32) and block (31) for the full load stop from the housing. 17. Remove the bolt that holds collar (33) to bolt (35). Remove collar (33) and spring (34) from bolt (35). Remove bolt (35) from the block.18. Remove the power adjustment screw from collar (33), if a replacement is necessary. 19. Remove bolts (37) and governor servo (36) from the fuel injection pump. The groove in the bottom of valve (38) must be in alignment with the servo body to permit removal from the fuel rack.20. Remove lockring (42), seat (41), spring (broken link spring) (40) and sleeve (39) from valve (38). Remove the other lockring (42) from the groove in the center of valve (38). 21. Remove valve (38), sleeve (43) and piston (45) from the governor servo. Remove the O-ring seal from sleeve (43).22. Remove pin (44) and lever (46) from the governor servo. 23. Use tool (C) to hold spring (48) in compression so ring (47) can be removed. Spring (48) is used to put a preload on the thrust bearing for the camshaft in the fuel injection pump housing.24. Remove ring (47), and remove tool (C). 25. Remove bearing (49), sleeves (50) and spring (48) from the governor shaft. 26. Remove ring (51) and dashpot assembly (52) from the governor shaft. 27. Use tool (B) to remove snap ring (58) from seat (55). Remove ring (57) and spool (56) from seat (55).28. Remove seat (55) from spring (54), and remove spring (54) from seat (53). 29. Remove spring (overfueling spring) (59) and riser (60) from the governor shaft. 30. Remove ring (61), races (62) and bearing (63) from the riser. Make a replacement of shield (64) any time it is removed.31. Use a screwdriver to remove shield (64) as shown. 32. Remove bolts (65) and carrier (66) for the governor flyweights. 33. Remove dowels (67) and flyweights (69) from the carrier.34. Remove shaft (68) from the carrier. Remove the dowel from shaft (68). 35. Remove races (70) and bearing (71) from the camshaft in the fuel injection pump housing.Assemble Governor
If the governor was removed only to permit repair of the fuel injection pump housing, do only Steps 1, 4, 5, 7, 9, 10, 11, 16, 22 and 38. Put clean oil on all parts before assembly. Be sure all oil passage are clear. 1. Install one race (70), bearing (71) and the other race (70) on the camshaft in the fuel injection pump housing. 2. Put flyweights (69) in position on carrier (66), and install the dowels to hold the flyweights in place. The flyweights must move freely on the dowels and have 0.010 to 0.23 mm (0.0004 to 0.009 in.) end play. 3. Install dowel (72) in governor shaft (68) and install the governor shaft in the carrier as shown. 4. Put carrier (66) in position on the camshaft, and install bolts (65) that hold the carrier in place.
Replace shield (64) with a new part any time it is removed.
5. Install shield (64) on the carrier, and use tool (D) to push the shield against its seat. Use a hammer and punch to move the metal (stake) two places on the side of the shield 180° 5° apart next to the holes in the shield. 6. Install one race (62), bearing (63), the other race (62) and use tool (B) to install ring (61) on riser (60) as shown. 7. Install riser (60) and the spring (overfueling spring) on the governor shaft as shown. 8. Assemble the dashpot as follows:a. Install spring (54) on seat (53), and install seat (55) in spring (54).b. Put spool (56) and ring (57) in position on seat (55), and use tool (B) to install snap ring (58) to hold them in place. 9. Install dashpot assembly (52) on the governor shaft as shown. 10. Install ring (51) in the lower groove in the governor shaft. Install one sleeve (50), spring (48), the other sleeve (50) and bearing (49) on the governor shaft as shown. Spring (48) is used to put a preload on the thrust bearing on the camshaft in the fuel injection pump housing. 11. Use tool (C) to hold spring (48) in compression, and install ring (47) in the groove in the governor shaft. Remove tool (C). 26. Install an O-ring seal on body (22) for the dashpot adjustment, and install the body in the housing.27. Install gasket