45915 Mercury TERMINAL BLOCK, EXHAUST MANIFOLD COVER SERIAL # THRU

1. Remove plate (1) from the left side of the flywheel housing. Bolt (2) is also the timing bolt for the flywheel. Some engines do not have the nut welded on the retainer. Use Step 2 on these engines.2. There are two ways the engine can be turned. The first way is as follows: a) Remove bolts (4) that hold pinion (3) and spacer (5) to the flywheel housing. b) Install pinion (3) in the flywheel housing. Use a 1/2" ratchet and turn the engine.3. The second way is as follows: a) The retainer (6) that holds the vibration damper and hub on the crankshaft has a 1 1/8" nut welded to it.b) Use a 1 1/8" socket and turn the engine. This will take two persons to do the procedure.4. Turn the engine clockwise (as seen from the flywheel) approximately 30° to remove the play in the timing gears. Turn the engine counterclockwise (as seen from the flywheel) until the threaded hole in the flywheel is in alignment with the hole in the flywheel housing and bolt (2) can be installed in the flywheel. The No. 1 piston is at top center compression stroke.5. The intake and exhaust valves for No. 1 cylinder on the right side of the engine must be free to move by hand. If not, it will be necessary to turn the engine counterclockwise (as seen from the flywheel) 360° more and install bolt (2) again. If the hole in the flywheel is turned beyond the hole in the flywheel housing, turn the engine clockwise (as seen from the flywheel) a minimum of 30° before the engine is turned counterclockwise (as seen from the flywheel) to install bolt (2).6. Remove the timing pin from the storage hole and install it in the timing hole in the fuel injection pump. Push the timing pin into the fuel injection pump housing and in the timing groove (slot) in the fuel injection pump crankshaft. The flange of the timing pin will be against the fuel injection pump housing if it is in all the way.7. If the timing pin does not go into the fuel injection pump camshaft, see CHECKING MOVEMENT OF THE VARIABLE TIMING UNIT and ADJUSTING VARIABLE TIMING UNIT DRIVE GEAR in TESTING AND ADJUSTING.
EARLIER MACHINE SHOWN Steps 8 through 10 are for earlier engines only.8. Remove tube assembly (7) from bracket (9) and the turbocharger.9. Remove tube assembly (8) from bracket (9) and the turbocharger.10. Remove bracket (9).
LATER MACHINE SHOWN11. Remove cover (10) from the engine. 12. Bend lock (12) away from the bolts.13. Remove the bolts, the lock and retainer (11). 14. Remove gear (13). 15. Remove the bolts, the locks, retainer (15) and shims that hold the variable timing unit in place.16. Remove variable timing unit (14) from the engine.Install Variable Timing Unit
1. Put variable timing unit (1) in position in the engine.
Install original amount of shims. There must be an end clearance (backlash) of .002 to .005 in. (0.05 to 0.13 mm) between the variable timing unit gear and the governor pinion gear when the governor drive is installed. Remove or add shims if necessary.
2. Install the original shims, the retainer, the lock and the bolts that hold variable timing unit (1) in position. 3. Put gear (2) in position on the variable timing unit. 4. Put retainer (3) in position. 5. Install lock (4) and the bolts. Do not tighten the bolts.6. Adjust gear (2). See ADJUSTING VARIABLE TIMING DRIVE GEAR (TIMING FUEL PUMP CAMSHAFT WITH NO. 1 PISTON AT TC COMPRESSION POSITION) in TESTING AND ADJUSTING.
EARLIER MACHINE SHOWN
LATER MACHINE SHOWN7. Install cover (8). Steps 8 through 10 are for earlier engines only.8. Install bracket (7) on the engine.9. Install tube assembly (5) on the turbocharger and the bracket.10. Install tube assembly (6) on the turbocharger and the bracket.end by:a) install valve cover (right side)b) install firewallc) install governorDisassemble And Assemble Variable Timing Unit
start by:a) remove variable timing unit 1. Remove pins (1) from weights (2). Remove weights (2). 2. Remove plug (3). Turn retainer (4) with a screwdriver. Remove the retainer and spring (5). 3. Pull piston (10) out of the shaft.4. Remove pin (11) from the coupling. Turn coupling (6) clockwise and remove it from the piston.5. Remove pin (7) from the nut. Remove nut (12), spring (8) and valve (9) from piston (10). The following steps are for assembly of the variable timing unit. 6. Install valve (9), spring (8) and nut (7) on piston (10). Turn nut (7) until the distance (X) between bottom face of nut (7) and piston (10) is 1.914 .015 in. (48.62 0.38 mm). Drill a .095 .002 in. (2.41 0.05 mm) diameter hole through the nut and threaded port of the piston. Install the pin. 7. Install coupling (6) tight against the nut. Measure a distance of .156 in. (3.96 mm) from the top face of the nut and put a mark on the coupling. Drill a .095 .002 in. (2.41 0.05 mm) diameter hole through the coupling and threaded portion of piston. Install the pin.8. Install piston (10) in the shaft. Install spring (5) and retainer (4).9. Install plug (3). The later variable timing nuts have a plug with an O-ring seal. The earlier variable timing units have a plug without an O-ring seal. For earlier variable timing units, tighten the plug to a torque of 75 10 lb.ft. (100 14 N m).10. Put weights (2) in position on the shaft and install pins (1). Make a mark (stake) with a punch at the pin holes in each end of the shaft to hold the pins in place. Each weight must move freely on its pin when installed.end by:a) install variable timing unit