880596T55 Mercury PUMP ASSEMBLY, Fuel - High Pressure

START BY:a. remove fuel injection linesb. remove fuel filter base and filter 1. Disconnect tube assembly (3) and hose assembly (4) from the fuel filter base.2. Remove bolt (1) and (5), and disconnect the two clips from the back of plate (6) that hold cable (2) and the wires.3. Remove one of the bolts that hold plate (6) to the frame, and disconnect the clip that holds tube assembly (3) to plate (6).4. Remove the other two bolts that hold plate (6) to the frame, and remove plate (6) and the fuel priming pump and filter group as a unit from the machine. 5. Remove six screws (7) and cover (8) from the governor control housing. 6. Put identification marks on lever (9) and the governor shaft for assembly purposes. Remove lever (9) from the governor shaft.7. Remove two bolts (11) and governor control housing (10) from the governor. 8. Disconnect both ends of hose assembly (12), and remove the hose assembly from the engine.9. Remove bolt (13), and remove the clip and the spacer from the fuel injection pump.10. Remove tube assembly (15) from the fuel transfer pump.11. Disconnect hose assembly (17) from the fuel transfer pump.12. Remove bolt (16), and disconnect the clip from the fuel transfer pump.13. Disconnect tube assembly (14) from the valve assembly on the fuel injection pump. 14. Remove the bolts, and disconnect tube assemblies (18) and (19) from the turbocharger.15. Loosen the connector, and disconnect tube assembly (18) from support (22).16. Remove the two bolts, and disconnect elbow (20) from support (22). Remove tube assembly (18) and (19) from the engine.17. Disconnect tube (21) from the bottom side of the governor. 18. Remove two bolts (24) that hold support (22) to the governor housing.19. Remove bolts (23) that hold support (22) to the engine, and remove the support. 20. Remove nuts (26) and cover (27) from the front housing cover.21. Remove the bolts and heat shield (25) from the engine. 22. Loosen bolt (29) until there is approximately 3.18 mm (.125 in.) gap between washer (28) and the fuel pump drive gear.23. Install tooling (A) as shown, and loosen the fuel pump drive gear from the taper on the fuel injection pump camshaft. Remove tooling (A) and bolt (29). 24. Fasten a nylon strap and hoist to fuel injection pump housing and governor (30) as shown.25. Remove nuts (31) that hold the injection pump housing and governor to the timing gear plate. Remove fuel injection pump housing and governor (30). The weight of the fuel injection pump housing and governor is 26 kg (58 lb.).Install Fuel Injection Pump Housing And Governor
Typical Example1. Put O-ring seals (1) and (2) in position on the fuel injection pump housing and governor. Put clean oil on the O-ring seals. 2. Fasten a nylon strap and hoist to fuel injection pump housing and governor (2) as shown.3. Put the fuel injection pump housing and governor in position on the timing gear plate, and install nuts (1) on the studs to hold it in place. 4. Remove bolts (4) and cover (3) from the fuel injection pump housing. 5. Install the bolt that holds the fuel pump drive gear to the fuel injection pump camshaft without the washer. This will allow the camshaft in the fuel system to be turned.6. Install tooling (A) in the fuel pump housing as shown. Put pressure on the end of tool (A), and turn the camshaft slowly until tool (A) drops into the groove (slot) in the camshaft. The fuel injection pump is in the No. 1 piston top dead center position. 7. With tooling (A) still in position, remove the bolt from the fuel injection pump camshaft.
Do not over tighten bolt (5) that holds the drive gear on the fuel injection pump. If the bolt is too tight, the gear will not be allowed to slip on the fuel injection pump shaft. This will cause the timing pin to break off in the notch of the camshaft when the flywheel is turned.
8. Install washer (6) and bolt (5) in the fuel injection pump camshaft with the large diameter of the washer toward the bolt head. Tighten the bolt to a torque of 6.8 N m (60 lb.in.). 9. Install tooling (B) in the flywheel housing. Make sure bolt (5) does not loosen as the flywheel is turned.10. Use tooling (B), and turn the flywheel in the direction of engine rotation (clockwise from the front of the engine) until bolt (7) [3/8"-16 NC x 4 in. (102 mm) long] can be installed in the flywheel. Do not turn the crankshaft counterclockwise to get the bolt aligned with the hole in the flywheel.11. If you go past the bolt hold in the flywheel, turn the crankshaft counterclockwise opposite the direction of engine rotation (as seen from the front of the engine) approximately 30 degrees. This procedure will permit the gear clearance (backlash) to be removed from the timing gears when the crankshaft is turned in the direction of engine rotation (clockwise).12. Repeat step 10 again. The rocker arms for No. 1 piston can be seen through the breather hole in the valve cover.13. Loosen clamp (9) and bolt (8) that hold the breather cap to the valve cover. Remove breather cap (10) and the O-ring seal from the valve cover. The No. 1 piston is at top center on the compression stroke when the bolt can be put in the flywheel through the hole in the flywheel housing, and both rocker arms for the No. 1 piston can be moved backward and forward by hand (have clearance with the valve stem).14. When both rocker arms are loose, tighten bolt (5) that holds the fuel pump drive gear to the fuel injection pump camshaft to a torque of 270 25 N m (200 18 lb.ft.)15. Remove tooling (A) and (B) and bolt (7) from the flywheel.16. Put the O-ring seal and breather cap (10) in position on the valve cover and