10202040 Mercury INSTALLATION MANUAL

1. Disconnect governor control linkage (1) from the governor.2. Remove the turbocharger oil supply line (2) and oil drain line (3).3. Remove all the fuel injection lines (4). Plug or cap all fuel lines and openings.4. Remove the six fuel injection pump housing-to-accessory drive housing mounting bolts (5).5. Remove the two elbow-to-fuel injection pump housing mounting bolts (6).6. Remove the fuel injection pump housing and governor as a unit - weight 50 lbs. (23 kg).Install Fuel Injection Pump Housing And Governor As A Unit
1. Locate top dead center compression stroke for No. 1 piston. See LOCATING TOP DEAD CENTER COMPRESSION POSITION FOR NO. 1 PISTON in TESTING AND ADJUSTING. 2. Install the timing fixture plate (A) on the rear face of the accessory drive housing.3. If the plate can be installed with the dowels in the accessory drive housing aligned with dowel holes in plate, the accessory drive shaft is correctly timed. Proceed to Step 8. If the plate cannot be installed, continue with Step 4.4. Remove the small cover from the front of the timing gear cover. Remove the timing gear retaining nut and lock. 5. Using tool setup (B), separate the gear from the accessory drive shaft. Rotate the accessory drive shaft until the timing fixture plate (A) can be installed. 6. Install the washer (with the outside diameter next to the gear) and the retaining nut on the drive shaft. Tighten the retaining nut to 100 10 lb.ft. (13,8 1,4 mkg).7. Install the cover on front of timing gear cover, and remove timing fixture plate (A).8. Position the fuel injection pump housing and governor on the engine, and install all mounting bolts.9. Remove all caps and plugs from lines and openings. Install the fuel injection lines. Tighten fuel injection line retaining nuts to 30 5 lb.ft. (4,1 7 mkg).10. Install the turbocharger oil supply line and the oil drain line. Connect control linkage to the governor.Separate Governor From Fuel Injection Pump Housing
preparatory step: a) remove fuel injection pump housing and governor as a unit 1. Remove the decelerator return spring (1) (if so equipped).2. Remove the idle screw cover (2).3. Remove the idle screw housing (3).4. Remove the rack stop collar retaining screw (4). 5. Remove the rack stop collar (5), collar (6), and spring (7).6. Remove the governor-to-fuel injection pump housing mounting bolts (8). 7. Remove the governor housing (9).8. Remove the governor spring (10), seat assembly (11), and washer-type spring (12).9. Remove the three mounting bolts (13) and lock that secure the cylinder and weight assemblies (14) to the fuel injection pump housing.10. Pull the cylinder and weight assemblies straight out to clear locating dowels. 11. Slide the cylinder and weight assemblies sideways to disengage slot in piston from the rack (15).Connect Governor To Fuel Injection Pump Housing
1. Position the cylinder and weight assemblies (1) on the fuel injection pump housing so that slot in piston is engaged with the rack (2).2. Push the cylinder and weight assemblies onto the locating dowels. 3. Install the three mounting bolts (3) and lock.4. Install the washer-type spring (4), seat assembly (5), and governor spring (6) on the cylinder assembly. The washer-type spring (4) should be installed so that the inside diameter of spring will contact the guide in governor housing (7).5. Position the governor housing (7) on the fuel injection pump housing, and install the governor mounting bolts. 6. Install the spring (9), collar (10), and rack stop collar (11) on bolt (8).7. Install and tighten the rack stop collar retaining screw (12). 8. Position the idle screw housing (13) on the governor so that dowel in housing engages slot in rack stop collar (11).9. Install the idle screw cover.10. Install the decelerator return spring.concluding steps: a) install fuel injection pump housing and governor as a unitb) set the rack and adjust governor (See FUEL RACK SETTING AND GOVERNOR ADJUSTMENTS in TESTING AND ADJUSTING)