89491 1 Mercury KEY 1A

1. Remove wiring harnesses from bracket (1). 2. Disconnect the wires at connections (5). Remove seal wire (4). Remove five bolts (2), bracket (1) cover (3) and the gasket. 3. Remove two bolts (6) and clamps. Remove rack solenoid (7). 4. Disconnect wires at connections (8). Remove two bolts (10) and bracket assembly (9). Loosen the locknut and remove rack position sensor (11). Be careful not to lose the spring that is around the sensor. To remove the transducer module at this time use the following procedure:a. disconnect wires at connector (8).b. remove the connectors from the wires.c. remove four bolts that fasten transducer module (22) to housing (18).d. feed the wires through housing (18) while removing the transducer module. 5. Remove three bolts (12) from inside housing (14). Remove two bolts (13) and remove housing (14).
Typical Example6. Loosen locknut (15) and remove engine speed sensor (16).
Typical Example7. Remove seven bolts (17) and remove the transducer module and housing (18). 8. Remove three bolts (19) and cover (20). 9. Remove two bolts (21). Remove transducer module (22) and gasket. 10. Remove lockring (27), seat (25), spring (24), sleeve (23) and lockring (26). 11. Remove three bolts (28) and remove cylinder (29). 12. Remove sleeve (30), piston (31) and valve (32). Remove O-ring seal (33) from sleeve (30). 13. Remove bolts (34) and remove retainer (35). Remove two races and one bearing (not shown). Assemble Rack Actuator Package
1. Lubricate bearing (37) with engine oil. Install race (36), bearing (37), race (36) and retainer (35) on the fuel injection pump camshaft. 2. Lubricate O-ring seal (33) with engine oil and install on sleeve (30). Install valve (32) and piston (31) into sleeve (33). 3. Install sleeve (30) into cylinder (29).4. Install lockring (26), sleeve (23), spring (24), seat (25) and lockring (27) on valve (32). 5. Put cylinder assembly (29) in position on the fuel injection pump housing with piston (31) engaged over fuel injection pump rack (38). Be sure that rack (38) is properly engaged with piston (31). 6. Fasten cylinder (29) to the fuel injection pump housing with three bolts (28). The rack and servo valve (32) must move freely after bolts (28) are tight. 7. Install gasket (39) and transducer module (22) on housing (18). 8. Place wire harness (40) in the slot of the housing. 9. Install cover (20) and bolts (19).
Typical Example10. Install the gasket and housing (18) on the fuel injection pump housing with seven bolts (17).
Typical Example11. Install engine speed sensor (16) until it contacts retainer (35). Back the engine speed sensor out (counterclockwise) 180°. This procedure will provide a clearance of .76 mm (.030 in). Tighten locknut (15).
Typical Example12. Install gasket and housing (14).13. Install the rack position sensor damping seal in housing (14). Install the spring and rack position sensor (11) in housing (14).14. Connect the rack position sensor wiring connector to the transducer module wiring connector (P1 to J1). Connect the transducer module wiring connector to the control module wiring connector (P5 to J5). See Illustration C42541P1. At this point of the assembly, see RACK POSITION SENSOR CALIBRATION in Testing And Adjusting. 16. Install bracket (9). Shut off lever assembly pin (42) must rest in yoke (41) of manual shut off shaft. 17. Check orientation of shut off lever assembly (43) with the governor servo valve, manual shut off control shaft and the shut off solenoid. 18. Connect wires at connections (8) and position in bracket (9). Wires inside of the housing must be positioned along the top of the housing.
Typical Example19. Lubricate O-ring seal (44) with engine oil and install on rack solenoid (7). Install rack solenoid (7) in the housing. The lever arm of solenoid (7) must engage with the groove in collar (23). 20. Install gasket and cover (3) with bolts (2). Install seal wire (4). Connect the wiring harness and install connectors (5) in the bracket.