89491 2 Mercury KEY 1B

Out Of Chassis
In Chassis1. Remove the plug, and move the rack until tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to remove the fuel injection pumps.
To prevent possible personal injury carefully follow the steps below.
2. Put tooling (B), except for the 8S4613 Wrench, in position on the fuel pump housing as shown. Lower the handle to center the adjusting screw with the fuel line seat. With the handle down in the locked position, the adjusting screw must just be in contact with fuel line seat (1). If force is needed to lower the handle or there is a gap, remove the tooling, and make an adjustment to the screw.3. Loosen bushing (2) 1/4 of a turn.4. Put tooling (B) in position on the pump housing with the handle down in the locked position as shown.5. Remove bushing (2) from the pump housing.6. Carefully and slowly lift the handle to release the spring force. Remove the tooling. 7. Install tool (C) on fuel pump (4) as shown.8. Remove seal (3) and fuel pump (4) from the fuel pump housing. 9. Remove spacers (5) from the pump housing. There must be a pump installed on either side of the pump to be removed to install tooling (B). If there is no pump, take a pump already removed, and remove the spring so there will be no spring force, and install it in the pump housing. See Install Fuel Pump. Spacers (5) are the same thickness for each fuel injection pump so they can be mixed. The fuel injection pump plungers and barrels are sets and cannot be mixed.Install Fuel Injection Pumps
1. Install spacers (5) in the fuel pump housing.2. Move the rack until tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to install the fuel injection pumps.3. Install a fuel pump without its spring so that tool (B) can be installed. See Step 5 for correct fuel pump installation. 4. Install tool (C) on the bonnet of the fuel pump as shown.5. Install the fuel pump in the pump housing with the saw cut (slot) (9) in the gear in alignment with small pin (6) in the lifter assembly and groove (8) in the barrel in alignment with large pin (7) in the pump housing. 6. Install the seal and bushing (2) on the fuel pump.7. Put tooling (B) in position on the fuel pump housing as shown.8. Lower the handle slowly and carefully. If the fuel pump is not installed correctly, the handle will not go all the way down. Do not try to use force on it. Remove and install the tooling and the fuel pump again.9. Make sure the seal is in its correct position, and start to tighten bushing (2). Remove the tooling, and tighten the bushing to a torque of 215 15 N m (160 11 lb.ft.).
Typical Example10. After each fuel pump has been installed, follow the steps below to check total rack travel to make sure each pump has been installed correctly.a. Install tooling (D) on the fuel pump housing as shown and zero the dial indicator.b. Remove tool (A) from the fuel pump housing.c. Move rack (10) in and out of the fuel pump housing to measure rack travel. Rack travel is approximately 9.62 mm (.379 in.) in the plus (full fuel) direction and 10.40 mm (.410 in.) in the minus (shutoff) direction. If this measurement is not obtained, center the rack, install tool (A), and remove and install the fuel pump again. One tooth off and rack travel is approximately 6.35 to 6.82 mm (.250 to .269 in.) in the plus direction and 7.02 to 7.05 mm (.276 to .278 in.) in the minus direction.a. install rack actuator packageb. install fuel injection linesDisassemble & Assemble Fuel Injection Pumps
See SMHS8378 for the correct tool usage.Start By:a. remove fuel injection pumps
Be careful when the injection pumps are disassembled. Do not damage the surfaces of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.
Do not remove the gear from the plunger. The gear and plunger are assembled and adjusted at the factory.1. Pull plunger (4) and washer (3) out of barrel (1) and spring (2).2. Remove spring (2) from barrel (1). 3. Use the following procedure to put the fuel pump in position on tooling (A):a. Select the correct turret position.b. Place a barrel assembly into the turret.c. Loosen the nut on the clamp.d. Adjust clamp end (6) until the bonnet is almost touching the barrel when the clamp handle is in the locked position.e. Tighten the nut on the clamp.4. Use tool (B) to expand ring (5), and carefully lift it off the fuel pump.5. Slowly release the clamp handle of tooling (A), and remove the lockring.6. Remove bonnet (7), spring (8) and valve (9) from barrel (1). The following steps are for assembly of the fuel injection pumps.
Put clean fuel on all parts during assembly.
7. Put spring (8) and valve (9) in bonnet (7).8. Put bonnet (7) barrel (1) and ring (5) in position on tool (A).9. Put the barrel assembly in position on tooling (A). Lower the handle on tool group (A) to hold the fuel pump together.10. Use tool (B), and lower ring (5) on to the barrel and the bonnet to hold them together.11. Remove the barrel assembly from tooling (B).12. Install spring (2) on barrel (1).13. Install washer (3) on plunger (4). Make sure the spring seat on the washer is away from the gear on the plunger.14. Install plunger (4) in barrel (1). Make