898103004 Mercury COVER, Intake Silencer

start by:a) remove fuel injection pump housing and governorb) remove governor
Be careful not to cause damage to the inlet and outlet ports on the bottom of the pump housing. The pump housing must be put on wood blocks before it is disassembled.
1. Remove the bolt and remove cover (2) and the gasket.2. Remove bolts (3) from housing assembly (1). Remove housing assembly (1) and the gasket. 3. Remove the shaft and gear from housing assembly (1). Remove bushing (4) from the housing assembly. 4. Remove bolts (7) from levers (9). Pull shaft (10) out of the pump housing. Remove levers (9), bushing (8) and the spring.5. Remove the two bolts (6) and remove cover (5). 6. Remove bolts (14) that hold retainer (16) and gear (17) to the pump camshaft. Remove the retainer and gear. When pinion gear (13) is removed, make a replacement of drive gear (11) with a new part.7. Remove idler gear (12). Remove pinion gear (13) from the pump housing with a soft hammer. Remove drive gear (11).8. Remove bypass valve (15). Remove the O-ring seals, pin, piston and spring from the valve body. 9. Remove bushing (18) from each of the injection pumps with tool (A). Remove washers (19).10. Put identification on each injection pump as to its location in the pump housing. Hold the fuel racks in the center (zero) position and carefully remove each injection pump with tool (B). 11. Remove the bolt that holds bracket (20) to the fuel injection pump housing. Remove bracket (20) and link (21).12. Put identification on the left rack (25) and right rack (24). Remove fuel racks (24) and (25). 13. Remove spacer (23) and lifter (22) from the pump housing. Put identification on each of the spacers and lifters as to their location in the pump housing. 14. Remove camshaft (26) from the pump housing.15. Remove the upper and lower bearings that hold the pinion gear in the pump housing. 16. Remove the dowel and idler gear shaft from the pump housing with tool group (C). 17. Remove fuel rack bearings (27) from the fuel pump housing. 18. Remove the lip type seals and bearings (29) from the pump housing with tooling (D).19. Remove the camshaft front and rear bearings (28) with tool group (E).Assemble Fuel Injection Pump Housing
1. Put fixture assembly (1) [part of tooling (A)] on the fuel pump housing with the dowels of the fixture in alignment with the left rack bore. Install the bolt that holds the fixture to the pump housing. 2. Put a new bearing (2) in position between the fixture and the fuel rack bore with the tab of the bearing up. Put driver (3) [part of tooling (A)] in alignment with the bearing until the shoulder of the driver makes contact with the bottom of the fixture.3. Turn the fixture and make alignment of the dowels in the fixture with the right rack bore. Install the bolts that holds the fixture to the pump housing.4. Do Step 2 for the left fuel rack bearing. 5. Install the camshaft front and rear bearings with tool group (B). Install the rear bearing until it is .19 in. (4.83 mm) from the rear surface of the pump housing. Install the front bearing until is .04 in. (1.02 mm) from the front surface of the pump housing. Make sure both oil holes in the bearings are in alignment with the oil holes in the pump housing. 6. Install the lip type seal in location (5) with tooling (C). Install the seal even with the outside surface and with the lip toward the outside.7. Install bearing (4) in the pump housing with tooling (D). Install the bearing until distance "X" is 1.505 .02 in. (38.23 0.51 mm). Dimension "X" is from the end of bearing (4) to the outer face of the pump housing base. 8. Install bearing (6) from the inside of the pump housing with tooling (E). The distance between bearings (6) and (4) must be 1.370 .020 in. (34.80 0.5 mm).9. Install the lip type seal in location (7) even with the inner housing surface and with the lip of the seal away from bearing (6). 10. Make sure the chamfer on the lower bearing for the pinion gear is toward the inside and use tooling (F) to install it. Install the bearing until it is even with the lower surface of the bearing bore.11. Make sure the chamfer on the upper bearing for the pinion gear is toward the inside and the notch is in the location shown. Use tooling (G) to install the bearing until it is even with the upper surface of the bearing bore. 12. Put clean engine oil on the camshaft and camshaft bearings. Install camshaft (8) as shown. 13. Install spring (10) and piston (9) in valve body (11). Install pin (12). Install seals (13).
Pin (12) must extend out from either side of the valve body.
14. Put clean engine oil on the O-ring seal and valve body. Install the oil bypass valve in the pump housing. 15. Install shaft (14) to a height of .66 .02 in. (16.8 0.5 mm) and dowel (15) to a height of .25 .02 in. (6.4 0.5 mm) above the surface of the pump housing.16. Install lifters (18) and spacers in their respective locations in the fuel pump housing. If new lifters and/or spacers are installed, make adjustment to the fuel pump timing dimension. See SETTING THE INJECTION PUMP TIMING DIMENSION: OFF ENGINE in TESTING AND ADJUSTING.17. Install the left fuel rack (16) and right fuel rack (17) on dowel and in the fuel pump housing. 18. Install link (20) in the notches of the fuel racks.19. Install bracket (19). Bracket (19) can turn when the bolt is tightened. Do not let the bracket turn. 20. Install tool (K) in the injection pump housing to hold the fuel racks in the center (zero) position.21. Install the injection pumps, bushings