828529 Mercury GUIDE

Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.Inspect the gears for wear or for damage. If the gears are worn or damaged, use new parts for replacement.Note: If one or more of the gears need to be removed for repair, refer to Disassembly and Assembly to remove the gears. Refer to the Disassembly and Assembly to install the gears.Backlash Between the Crankshaft Gear, the Camshaft Gear, and the Fuel Injection Pump Gear
Table 2
Record Backlash Measurement Crankshaft Gear Tooth Crankshaft Gear / Fuel Injection Pump Gear Angle (Degrees) Camshaft Gear Angle (Degrees)
1 0 0 0
2 11 90 45
3 23 180 90
4 34 270 135
5 46 360 180
6 57 450 225
7 69 540 270
8 80 630 315
9 96 720 360 Backlash Between the Crankshaft Gear and the Camshaft Gear
Use Tooling (A) to rotate the crankshaft so that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, Finding Top Center Position for No.1 Piston for the correct procedure.
Make a temporary mark on the top tooth of the crankshaft gear. Refer to illustration. Move in a counterclockwise direction and make a temporary mark in the next tooth (number "11"). Make a temporary mark in the next tooth (number "23"). Make a temporary mark in the next tooth (number "34").Note: The top tooth of the crankshaft gear is number "0" and number "46". Make a note of the starting point and the direction of rotation.
Mount Tooling (C) on a suitable flat surface to measure the backlash between the crankshaft gear and the camshaft gear. Ensure that the finger attachment is vertical. Ensure that the point of the finger attachment is in contact with the gear. The backlash measurement point is half way down the pitch circle diameter and along the relevant tooth.
Set the dial gauge indicator to zero. Gently rotate the camshaft gear backwards and forwards. Measure the backlash between the crankshaft gear and the camshaft gear. Refer to Specifications, "Gear Group (Rear)" for the backlash measurement.
Remove Tooling (B) from the camshaft.
Use Tooling (A) to rotate the crankshaft in a clockwise direction until the next crankshaft tooth (number "11") is located between the camshaft gear teeth.
Gently rotate the camshaft gear backwards and forwards. Measure the backlash between the crankshaft gear and the camshaft gear. Refer to Specifications, "Gear Group (Rear)" for the backlash measurement.
Use Tooling (A) to rotate the crankshaft in a clockwise direction until the next crankshaft tooth (number "23") is located between the camshaft gear teeth.
Gently rotate the camshaft gear backwards and forwards. Measure the backlash between the crankshaft gear and the camshaft gear. Refer to Specifications, "Gear Group (Rear)" for the backlash measurement.
Use Tooling (A) to rotate the crankshaft in a clockwise direction until the next crankshaft tooth (number "34") is located between the camshaft gear teeth.
Gently rotate the camshaft gear backwards and forwards. Measure the backlash between the crankshaft gear and the camshaft gear. Refer to Specifications, "Gear Group (Rear)" for the backlash measurement.
Use Tooling (A) to rotate the crankshaft in a clockwise direction until the next crankshaft tooth (number "46") is located between the camshaft gear teeth.Note: At this point, the crankshaft gear has completed one revolution.
Gently rotate the camshaft gear backwards and forwards. Measure the backlash between the crankshaft gear and the camshaft gear. Refer to Specifications, "Gear Group (Rear)" for the backlash measurement.
Use Tooling (A) to rotate the crankshaft in a clockwise direction until the next crankshaft tooth with the temporary mark is in the correct position. Refer to table 2 for more information.
Use Tooling (A) to rotate the crankshaft in a clockwise direction until the crankshaft has completed two complete revolutions. If the first recorded backlash measurement is greater than 0.001 mm (0.00004 inch) of the value of the last recorded backlash measurement, repeat step 4 through step 14.Backlash Between the Camshaft Gear and the Fuel Injection Pump Gear
Use Tooling (A) to rotate the crankshaft so that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, Finding Top Center Position for No.1 Piston for the correct procedure.
If necessary, make a temporary mark on the top tooth of the crankshaft gear. Refer to illustration. Move in a counterclockwise direction and make a temporary mark in the next tooth (number "11"). Make a temporary mark in the next tooth (number "23"). Make a temporary mark in the next tooth (number "34").Note: The top tooth of the crankshaft gear is number "0" and number "46". Make a note of the starting point and the direction of rotation.
Mount Tooling (C) on a suitable flat surface to measure the backlash between the camshaft gear and the fuel injection pump gear. Ensure that the finger attachment is vertical. Ensure that the point of the finger attachment is in contact with the gear. The backlash measurement point is half way down the pitch circle diameter and along the relevant tooth.
Set the dial gauge indicator to zero. Gently rotate the fuel injection pump gear backwards and forwards. Measure the backlash between the camshaft gear and the fuel injection pump gear. Refer to Specifications, "Gear Group (Rear)" for the backlash measurement.
Remove Tooling (B) from the camshaft.
Use Tooling (A) to rotate the crankshaft in a clockwise direction until the next crankshaft tooth (number "11") is located between the camshaft gear teeth.
Gently rotate the fuel injection pump gear backwards and forwards. Measure the backlash between the camshaft gear and the fuel injection pump gear. Refer to Specifications, "Gear