39043 Mercury SEAL, STARTER HOUSING TO TOP COWL

start by:a) remove fuel injection lines1. Fasten a hoist and remove the hood over the engine. Weight is 77 lb. (35 kg).2. Close the three fuel valves on the fuel tank. Disconnect two fuel lines from the fuel filter. Disconnect air line from the governor control rotochamber. 3. Disconnect two wires (1) from the fuel shutoff solenoid. Disconnect tube (2) from the fuel ratio control. 4. Remove bracket (3). 5. Put identification on wires (4) for the fuel pressure switch. Disconnect the wires from the switch. Disconnect fuel line (5) from the union.6. Remove fuel filter base (6) from the fuel injection pump housing. 7. Remove the bolt that holds vent line (8) to the cylinder block.8. Remove bolts (9) and move the clip on the breather tube clear of the fuel injection pump housing.9. Disconnect lines (7) and (10) from the fuel injection pump housing. 10. Remove cover (11) from the timing gear cover.
TYPICAL EXAMPLE11. Loosen bolt (12) until there is approximately 1/8in. (3.2 mm) clearance between the bolt head and washer.
TYPICAL EXAMPLE12. Install tool (A) on the fuel injection pump drive gear and automatic timing advance as shown. Use tool (A) to loosen the drive gear.13. Remove tool (A), bolt (12) and the washer. 14. Remove turbocharger lubrication return line (13).15. Fasten a hoist to the fuel injection pump housing and governor. Remove three nuts (14) and remove the fuel injection pump housing and governor. Weight is 57 lb. (26 kg).Install Fuel Injection Pump Housing And Governor
1. Put the number one piston in top center compression position. See "FINDING TOP CENTER COMPRESSION POSITION FOR NO. 1 PISTON" in TESTING AND ADJUSTING FORM NO. SENR7355. 2. Remove bolt (2). 3. Remove timing pin (1) from the cover of the governor housing.4. Put timing pin (1) in the hole for bolt (2). Turn the camshaft until pin (1) goes in the notch in the camshaft.5. Fasten a hoist and install the fuel injection pump housing and governor on the engine. Install the three nuts that hold pump housing to the timing gear plate.6. Put the fuel injection pump drive gear and automatic timing advance in position on the camshaft and install the washer and bolt that hold it.
TYPICAL EXAMPLE7. Install tooling (A) in the holes of the fuel injection pump drive gear as shown. Put a torque of approximately 50 lb.ft. (70 N m) on the pump drive gear in a clockwise direction (as seen from the front of the engine). With the clockwise torque on the pump drive gear tighten the bolt to a torque of 110 5 lb.ft. (149 7 N m).8. Remove the timing pin (1). Remove the 3/8"-16 NC bolt from the flywheel.9. Turn the engine flywheel counterclockwise (as seen from rear of engine) two complete revolutions. If the timing pin (1) goes into the notch in the camshaft and the 3/8"-16 bolt goes into the flywheel at the same time, the timing is correct.10. If the timing pin (1) can not be installed see "CHECKING TIMING BY TIMING PIN METHOD" in TESTING AND ADJUSTING FORM NO. SENR 7355. 11. Install cover (3) on the timing gear cover.12. Install the turbocharger lubrication return line. 13. Connect fuel lines (4) and (7) to the fuel injection pump housing.14. Install bolts (6). Install the bolt that holds vent line (5) to the cylinder block. 15. Install fuel filter base (8).16. Connect wires (9) to the fuel pressure switch in their original position.17. Connect fuel line (10) to the union. 18. Install bracket (11). 19. Connect tube (12) to the fuel ratio control.20. Connect wires (13) to the fuel shutoff solenoid.21. Connect the air line to the governor control rotochamber.22. Connect the two fuel lines to the fuel filter.23. Open the three fuel valves on the fuel tank.24. Fasten a hoist and install the hood over the engine.end by:a) install fuel injection lines