803509020 Mercury SCREW ASSEMBLY, Pilot

Install Spring Washers As Shown(3) Seat. Install a spring washer, flat washer and spring washer between seat (3) and spring (4) as shown.(4) 4N6681 Spring for the governor: Color code ... two purple stripesPut force on spring of ... 22.24 N (4.00 lb)Then add more force to make spring shorter by ... 22.86 mm (.900 in)Total test force ... 66.00 2.00 N (14.80 .48 lb)Free length after test ... 56.9 .08 mm (2.24 .04 in)Outside diameter ... 34.80 mm (1.37 in)(4) 9L6448 Spring for the governor: Color code ... one green stripe, one yellow stripePut force on spring of ... 22.24 N (4.00 lb)Then add more force to make spring shorter by ... 22.86 mm (.900 in)Total test force ... 73.00 1.50 N (16.60 .30 lb)Free length after test ... 56.9 .08 mm (2.24 .04 in)Outside diameter ... 35.30 mm (1.39 in)(5) 9M6303 Spring for low idle performance (PC Governor): Length under test force ... 4.57 mm (.180 in)Test force ... 45 4 N (10 1 lb)Free length after test ... 8.74 (.344 in)Outside diameter ... 12.19 mm (.480 in)(5) 8N6579 Spring for low idle performance (DI Governor): Color code ... 1 yellow stripeLength under test force ... 6.35 mm (.250 in)Test force ... 2.62 0.13 N (.60 .03 lb)Free length after test ... 13.84 1.00 mm (.545 .039 in)Outside diameter ... 11.11 mm (.437 in)(6) Diameter of the outer surface of the cylinder (new) ... 38.100 0.013 mm (1.5000 .0005 in)Bore in the gear (new) ... 38.151 0.013 mm (1.5020 .0005 in).(7) Install two dowels in governor drive gear to a dimension of ... 7.9 0.5 mm (.32 .01 in)(8) Bore in the bearing (new) ... 22.263 0.038 mm (.8765 .0015 in)Diameter of the gear at the hub (new) ... 22.187 0.013 mm (.8735 .0005 in).
Earlier Governors
Governor Plate(9) Distance from the face of the plate to the bearing for the governor drive assembly ... 0.51 0.25 mm (.020 .010 in)(10) Dowel installation: Angle A must be ... 54 10°Dimension B must be ... 7.9 0.5 mm (.31 .02 in)(11) Install dowels to get a dimension of ... 5.6 0.5 mm (.22 .02 in)
Control Shaft Bearings(12) Bore in the governor control shaft bearings (after assembly) ... 15.761 0.038 mm (.6205 .0015 in) Diameter of the governor control shaft (new) ... 15.720 0.008 mm (.6189 .0003 in)(13) Distance between the bearings for the governor control shaft ... 60.58 0.13 mm (2.385 .005 in)(14) Distance from the face of the housing to the end of the bearing for the governor control shaft ... 43.38 0.15 mm (1.708 .006 in)
Shutoff Shaft Bearings(15) Bore in the shutoff shaft bearing (new) ... 12.713 0.013 mm (.5005 .0005 in) Diameter of the shutoff shaft (new) ... 12.637 0.013 mm (.4975 .0005 in)(16) Torque for insulator ... 4.5 0.6 N m (40 5 lb in)(17) Needle bearing.(18) Distance from center of bolt hole to outside end of needle bearing (17) ... 92.86 0.25 mm (3.656 .010 in)(19) Distance from end of needle bearing (17) to inside of sleeve bearing ... 98.68 0.25 mm (3.885 .010 in)Install seals as shown.