89771 1 Mercury CONNECTOR-FUEL TANK END

1. Time the engine as follows:a. Install tooling (A) in the flywheel housing.b. Remove the cover from the side of the fuel injection pump housing so the timing pin can be installed. Remove the plug from the flywheel housing so the timing bolt can be installed.c. Turn the engine in the direction of engine rotation until tooling (B) can be installed in fuel injection pump housing and located in the groove in the fuel injection pump camshaft, a 3/8" - 16 NC bolt can be installed in the flywheel through the hole in the flywheel housing, and the "C" marks on the crankshaft gear and the camshaft gear are in alignment with each other. For more information on timing the engine, see Checking Timing By Timing Pin Method in Testing And Adjusting.2. Loosen bolt (1) until there is approximately 3.18 mm (.125 in.) gap between washer (2) and fuel pump drive gear (3).3. Install tooling (C) as shown, and loosen the fuel pump drive gear from the taper on the fuel injection pump camshaft. Remove tooling (C), the bolt, washer and fuel pump drive gear.4. Remove the bolts and plate (4) that hold idler gear (5) in position. Remove the idler gear. If necessary, remove the bearing from the idler gear with tooling (D) and a press.
Do not turn the crankshaft after camshaft gear (6) has been removed. Turning the crankshaft will cause damage to the valves.
5. Remove the four bolts that hold camshaft gear (6) to the camshaft. Remove the camshaft gear.Install Timing Gears
1. Make an alignment of the "C" marks on crankshaft gear (3) and camshaft gear (4). Install the camshaft gear and the bolts that hold it. Tighten the bolts to a torque of 55 7 N m (41 5 lb. ft.).2. Install the bearing in idler gear (1) with tool (A). The end of the bearing must be 1.52 mm (.060 in.) below the face of the gear hub after installation.3. Be sure the oil hole in the shaft for idler gear (1) is open. Put idler gear (1) and plate (2) in position on the shaft, and install the bolts that hold them.4. Make sure tooling (C) is in position in the groove of the fuel injection pump camshaft.
Do not over tighten bolt (7) that holds the drive gear on the fuel injection pump. If the bolt is too tight, the gear will not be allowed to slip on the fuel injection pump shaft. This will cause the timing pin to break off in the notch of the camshaft when the flywheel is turned.
5. Put fuel injection pump drive gear (5) in position on the fuel injection pump camshaft. Put washer (6) in position on the gear with the largest diameter toward the front of the engine. Install bolt (7), and tighten it to a torque of 6.8 N m (60 lb. in.). Make sure bolt (7) does not turn while the flywheel is being turned.6. Remove the timing bolt from the flywheel, and use tooling (B) to turn the flywheel in the opposite direction of engine rotation. Turn the flywheel until the "C" mark on the crankshaft gear moves 30°.7. Turn the flywheel in the direction of engine rotation until the timing bolt can be installed in the flywheel and the "C" marks are in alignment. This will remove all of the backlash from the timing gears.8. Tighten bolt (7) to a torque of 270 25 N m (200 18 lb. ft.).9. Remove tooling (B) and (C). Remove the timing bolt from the flywheel. Install the covers on the flywheel housing and fuel injection pump housing. Install the plug in the flywheel housing.END BY:a. install timing gear cover