841916R01 Mercury SERVICE MANUAL

Illustration 1 g00385512
Fuel injection pump (1) Union nut for high pressure fuel line (2) Union nut for the fuel return line (3) Fuel delivery valve (4) Mounting bolts and nuts for the fuel injection pump (5) Bolt for the fuel supply line
Illustration 2 g00403238
Temporary arrangement for checking the timing of the fuel injection pump (6) Line (7) Dial indicator (8) Throttle lever
Set the piston of number one cylinder on the compression stroke. Position the plunger of the dial indicator on the inlet valve of number 1 cylinder. Refer to Testing and Adjusting, "Finding Top Center Positionor No. 1 Piston". When the number 1 piston is at the top center position, set the dial indicator to zero.
Remove the fuel shutoff solenoid.
Disconnect the high pressure fuel line to number 1 cylinder (1) .Note: When the fuel delivery valve is removed from the fuel injection pump, the crankshaft must not be rotated. If the crankshaft is rotated, the fuel injection pump will be damaged.
Illustration 3 g00398707
Components of the fuel delivery valve (3) Valve body (9) Location pin (10) Spring (11) Valve pin (12) Washer (13) Seat
Remove valve body (3) for number 1 cylinder. Disassemble the fuel delivery valve.Note: All components of the fuel delivery valve must be kept clean. Keep the components in clean diesel fuel.
Reassemble the fuel delivery valve with the following components:
Valve body (3)
Washer (12)
Seat (13)
Remove the fuel supply line. Connect a fuel supply tank with a capacity of 0.75 L (0.8 qt).The fuel tank should be above the fuel injection pump in order for gravity to provide the flow of fuel to the fuel injection pump. The bottom of the fuel tank should be at least 152 mm (6 inch) above the fuel injection pump in order to provide sufficient pressure. Connect a line with a valve between the fuel tank and the fuel supply line. Tighten the bolt for the fuel supply line to a torque of 20 N m (15 lb ft).
Connect a curved line (6) to delivery valve holder (3) for number 1 cylinder. Put a suitable container beneath the outlet of the curved line in order to collect the fuel which flows from the delivery valve.
Add 0.5 L (0.5 qt) of clean fuel to the fuel tank. Open the valve between the fuel tank and the fuel supply line.Note: Ensure that throttle lever (8) is held in the maximum fuel position during this procedure.
Rotate the crankshaft in a counterclockwise direction until the pointer of dial indicator (7) moves in a counterclockwise direction at least 5.08 mm (0.200 inch).
Turn the crankshaft slowly in a clockwise direction until the flow of fuel from curved line (6) decreases to one drop for every 7 to 10 seconds.
Observe the reading of the dial indicator. This reading is the piston position. If the timing is correct, the reading for the piston position will be 2.54 mm (0.100 inch). If the reading is less than 2.54 mm (0.100 inch), the timing is retarded. Install a thinner shim in order to advance the timing to the required specification.If the reading is greater than 2.54 mm (0.100 inch), the timing is advanced. Install a thicker shim in order to retard the timing to the required specification.The timing will change one degree for each 0.10 mm (0.004 inch) of thickness of the shim.
Install a new shim of the correct thickness. Then, perform Steps 10 through 11.
When the timing of the fuel injection pump is correct, remove the fuel tank, the valve, the curved line (6), and the dial indicator (7) .Remove valve body (3), washer (12), and seat (13). Assemble the components of the fuel delivery valve. Refer to Illustration 3 for the correct sequence of components. Install the fuel delivery valve.Install valve mechanism components and the fuel shutoff solenoid. Install all fuel lines in the correct position. Tighten all nuts and bolts to the correct torque. Refer to Specifications, "Fuel Injection Pump".