880515 Mercury BOLT, (M20 x 68)

start by:a) disassemble governorb) remove fuel transfer pump 1. Remove shutoff solenoid (1) and the gasket from the cover. 2. Remove bolts (2) and flanges (3) from the cover. 3. Inspect check valve (4) in the flange and remove the check valve if a replacement is necessary. 4. Remove bolts (5) and cover (6) from the fuel injection pump housing. 5. Remove bolts (7) and (8) and remove the shut-off housing assembly from the bottom of the cover. 6. Remove screws (9) and lever (10) from shaft assembly (12). Remove shaft assembly (12) and shaft (11) from the shutoff housing. 7. Remove seal (13) from the shutoff housing. 8. Remove spring (14) and the bypass valve from the housing. Put identification on the fuel injection pumps for installation in their respective bores in the housing. 9. Install tooling (A) on the fuel injection pump and loosen the bushing from the pump housing. Remove the fuel injection pump from the pump housing. The sleeve on the plunger will slide off the lever as the pump is removed. Remove all the fuel injection pumps from the housing. 10. Remove high idle adjustment screw (15). 11. Loosen four screws (16) in the levers and remove screw (18) in the crossover lever. Slide shaft assembly (17) out of the housing. 12. Loosen the four screws in levers (19) and remove the screw in crossover lever (20). Slide shaft (21) out of the housing. 13. Use a magnet to remove eight lifter assemblies (22). Put identification on lifters (22) and rollers (23) for installation in their respective bores in the housing. 14. Remove roller (23) from each lifter assembly. 15. Use a small punch and hammer to push dowel (24) out of the housing. 16. Remove O-ring seal (25) from the dowel. 17. Turn the camshaft so the groove (slot) for the timing pin is in the position shown and carefully remove camshaft (26). Remove the thrust washer from the housing. 18. Remove camshaft rear bearing (27) from the fuel pump housing. Be careful to not damage the bearing bore in the housing. 19. Use tooling (B) to remove the camshaft front bearing from the fuel pump housing. Earlier fuel pump housings do not have a thrust washer for the camshaft. The 6V4068 Tool Group can be used to machine the housing so the 9N5822 Thrust Washer can be used. See SPECIAL INSTRUCTION Form SMHS7897 for the procedure to machine the housing.Assemble Fuel Injection Pump Housing
Put clean fuel on all parts during assembly. 1. Use tooling (A) to install the camshaft front bearing in the housing. Install the bearing with the chamfer toward the inside of the pump housing. Install the bearing so it is even with the front face of the pump housing. 2. Use tooling (B) to machine the bore in the camshaft front bearing to the correct size. See SPECIAL INSTRUCTION Form SMHS6735 for the procedure to machine the new camshaft front bearing. The bore in the bearing must be 25.413 0.013 mm (1.0005 .0005 in.). 3. Use tooling (A) to install the camshaft rear bearing in the housing. Install the bearing so groove (1) in the bearing is in the position shown. On earlier pump housings without a thrust washer install the bearing into the bore so the outer face of the bearing is 0.114 0.025 mm (.0045 .0010 in.) below face (X) on the housing. On later pump housings with a thrust washer install the bearing into the bore so the outer face of the bearing is 0.43 0.13 mm (.017 .005 in.) below the counterbore for the thrust washer. 4. Install thrust washer (2) in the housing with the ear on the thrust washer in the hole in the pump housing so the thrust washer will not turn.5. With the pump housing in a vertical position as shown carefully install camshaft (3).6. To make sure that the thrust washer will be kept in its correct installation location, keep the pump housing in a vertical position, and install the fuel transfer pump and camshaft sleeve. See FUEL TRANSFER PUMP INSTALLATION for the procedure to install the fuel transfer pump and camshaft sleeve.
If the pump housing is assembled while it is in a horizontal position, the thrust washer can slide out of the counterbore and into the area between the camshaft thrust face and the housing. Then the fuel pump camshaft end play will not be correct and it will be necessary to disassemble the fuel pump housing so the thrust washer can be installed correctly.
7. Install the O-ring seal on dowel (4) and install the dowel in the pump housing. 8. Install each roller (5) in their respective lifter. 9. Use a magnet to install lifter assemblies (6) in their respective bores in the pump housing with the groove in each lifter in alignment with the dowel in the lifter bore. 10. Install shaft (7) in the pump housing, then through one lever (8), then through crossover lever (9), then through three levers (8) as shown. Install the screw in crossover lever (9) but do not tighten any of the screws in the levers. 11. Install shaft assembly (10) in the pump housing, then through one lever (12), then through crossover lever (11), then through three levers (12) as shown. Install the screw in crossover lever (11) but do not tighten any of the screws in the levers. 12. Install high idle adjustment screw (13) and the locknut. 13. Use tooling (A) to install the seal in the shutoff housing with the lip out as shown. 14. Install the shaft for levers (14) and (16) and shaft (15) in the shutoff housing. Put levers (14) and (16) in position on the shaft and install the screws that hold the levers to the shaft. Be sure lever (16) is engaged in the groove in shaft (15) as shown. 15. Put the gasket and cover (17) in position on the shutoff housing. 16. Install