897543A01 Mercury CAP ASSEMBLY, Connector - 2 Way

start by:a) remove muffler and hoodb) remove shutoff solenoidc) remove fuel ratio controld) remove fuel injection linese) remove fuel transfer pump1. Remove timing bolt (1), cover (2) and plug (3). 2. Use tool (A) to turn the engine in a counterclockwise direction (as seen from the flywheel end of the engine) until the No. 1 piston is at top center on compression stroke. Install timing bolt (1) in flywheel. See FINDING TOP CENTER COMPRESSION POSITION FOR NO. 1 PISTON, SYSTEMS OPERATION TESTING AND ADJUSTING. 3. Remove the plug from the front of the injection pump housing. Install tool (B) (as shown) through the hole in the pump housing and into the timing notch in the fuel injection pump camshaft. 4. If timing is correct, tool (B) will go into the notch in the fuel injection pump camshaft and the timing bolt will turn freely into the threaded hole in the flywheel. If timing is not correct, remove tool (B) and the timing bolt and do the following procedure:a) Remove the small cover from the automatic timing advance cover.b) Make sure tool (B) is removed from the fuel injection pump camshaft. Loosen four bolts which hold the automatic timing advance unit on the fuel pump camshaft.c) Tighten the bolts with fingers until there is a small amount of friction (slight drag) between the retainer and the timing advance unit. This will prevent movement (backlash) when the gears are turned to the correct timing.d) Use tool (A) to turn the engine in a counterclockwise direction (as seen from the flywheel end) until tool (B) can be installed in the fuel injection pump camshaft.e) Use tool (A) to turn the engine in a clockwise direction (as seen from the flywheel end) a minimum of 30 degrees to remove the movement (backlash) in the timing gears.f) Use tool (A) to turn the engine in a counterclockwise direction (as seen from the flywheel end) until the No. 1 piston is at top center compression stroke. Install the timing bolt in the flywheel.g) Tighten the bolts that hold the automatic timing advance to a torque of 25 N m (20 lb.ft.). Remove tool (B) from the fuel injection pump camshaft.h) Tighten the bolts to a torque of 135 7 N m (100 5 lb.ft.). Remove the timing bolt (1) from the flywheel.5. Turn the engine two complete revolutions and check the timing again. If tool (B) will not go into the notch of the fuel injection pump camshaft, do Steps a through h again.6. Disconnect clip (4) and nut (6) for the fuel line (5). 7. Put a protective cap and protective plug in the fuel line (5) openings.8. Remove bracket (7) and bolts (8). 9. Remove bolts (9) and bracket (10). 10. Remove cover (11). 11. Remove bolts (12) that hold the retainer and automatic timing advance unit to the fuel injection pump camshaft. 12. Fasten tooling (C) to the fuel injection pump housing with two 3/8" - 16 NC bolts 2 1/4" long. Fasten a hoist to tooling (C). 13. Remove fuel injection pump housing and governor (13). The weight of the fuel injection pump housing and governor is 47 kg (103 lb.).Install Fuel Injection Pump Housing And Governor
1. Check O-ring seal (1) for wear or damage. If necessary, make a replacement. Put a small amount of 1P808 General Purpose Grease on the O-ring seal. 2. Install tool (B) in the notch of the fuel injection pump camshaft.3. Fasten tooling (A) to the fuel injection pump housing with two 3/8"-16 NC bolts 2 1/4" long. Fasten a hoist to tooling (A). Put fuel injection pump housing and governor in position on the top of the engine. 4. Install bolts (2) and bracket (3).5. Install bolts (5) and bracket (4). 6. Connect clip (7) and nut (8) for fuel line (6). 7. Install bolts (9) to hold the automatic timing advance unit and retainer to the end of the fuel injection pump camshaft. 8. Check the engine timing. See REMOVE FUEL INJECTION PUMP HOUSING AND GOVERNOR, Steps 1 through 5.9. Install the gasket and cover (10) on the timing advance unit cover after the bolts have been tightened. 10. Remove tool (B) and install the plug in the fuel injection pump housing. 11. Remove tool (C). Install the cover and plug on the right side of the flywheel housing.end by:a) install fuel transfer pumpb) install fuel injection linesc) install fuel ratio controld) install shutoff solenoide) install muffler and hood