41493A 9 Mercury TRIM CYLINDER ASSEMBLY

START BY:a) remove fuel injection pump housing and governorb) remove governor drive housing (Woodward Governor only)c) remove governor (hydramechanical only)1. Remove the protection caps and the felt washers from the pumps.2. Use tool (A) to remove the bushing that holds the pumps in the fuel injection pump housing. 3. Remove seal (1) from the fuel injection pump housing. 4. Install tool (C) on the end of the fuel injection pump housing as shown.
Woodward Governor Shown5. Move the adapter and rack (Woodward Governor) or rack (hydraulic governor) against tool (C) to center the rack and use tool (B) to remove fuel injection pump (2) from the fuel injection pump housing. 6. Remove spacer (3) from the fuel injection pump housing.7. Repeat Steps 1-6 for removal of the remaining fuel pumps. Put identification on the injection pumps and spacers as to their location in the pump housing. 8. Remove adapter (7) and the rack from the fuel injection pump housing (Woodward Governor only). Remove the rack from the fuel injection pump housing (hydramechanical governor only).9. Bend tabs of lock (5) away from bolts (4). Remove bolts (4) and guide (6) from the fuel injection pump housing (Woodward governor only). 10. Remove adapter (7) and spring (8) from rack (9) (Woodward Governor only). 11. Remove lifters (10) from the fuel injection pump housing. Keep lifters together with identification as to their location in the pump housing. 12. Bend lock (12) away from bolts (11). Remove bolts (11), locks (12), the sleeves and gear (13) from the camshaft. 13. Remove pin (16) and spring (14) from gear (13).14. Remove pin (17) and yoke (15) from spring (14). 15. Remove plate assembly (18) and the gasket from the fuel injection pump housing. 16. If necessary, remove bushing (19) from the plate assembly. 17. Remove bolts (21) plate (23) and spacer (22) that hold camshaft (20) in the fuel injection pump housing.18. Remove camshaft (20) from the fuel injection pump housing. 19. If necessary use tool group (D) and remove the camshaft bearing from the automatic timing advance end of the fuel injection pump housing.20. If necessary, remove rack bearing (24) from the automatic timing advance end of the fuel injection pump housing. 21. If necessary remove rack bearing (25) and dowels (26) from the governor drive housing end of the fuel injection pump housing.22. If necessary, use tool group (D) and remove camshaft bearing (27) from the governor drive housing end of the fuel injection pump housing and the center bearing in the fuel injection pump housing.Assemble Fuel Injection Pump Housing
1. Use tooling (A) to install the camshaft bearings in fuel injection pump housing (1). Install the camshaft bearings so that the bearing joints are 15° from the vertical centerline of the bores. Install the front and rear camshaft bearings even with the outside surfaces of fuel injection pump housing (1). Install the center camshaft bearing to a distance of 122.2 0.5 mm (4.81 .02 in.) from rear face (X). After assembly the inside diameter of the camshaft bearings must be 53.988 0.038 mm (2.125 .01 in.). 2. Use tooling (B) and install the rack bearing even with the outside surface of fuel injection pump housing (1). Make sure the tab in the rack bearing is installed toward the inside and within .05 mm (.003 in.) of the vertical center line of the bearing bore. After assembly the inside diameter of the rack bearing must be 12.758 0.046 mm (.502 .002 in.). 3. Use tool group (C) to install the rear rack bearing. Install the rack bearing to a depth of 7.16 0.13 mm (.282 .005 in.) below the outside surface. The small holes in the rear rack bearing must be installed parallel to the vertical centerline of the bearing bore. After assembly the inside diameter of the bearing must be 12.746 .046 mm (0.502 0.002 in.).4. Install dowels (2) in the fuel injection pump housing 15.7 0.5 mm (0.618 0.02 in.) above the outside surface. 5. Put clean engine oil on camshaft (3) and carefully install it in the fuel injection pump housing.6. Install spacer (4), plate (5) and the bolts that hold camshaft (3) in place. 7. Make sure all gasket surfaces are clean and free of dirt.8. Put gasket (6) in position on the fuel injection pump housing. 9. Use tool group (C) and install bushing (8) in plate assembly (7) even with outside surface (X).10. Put plate assembly (7) in position on the fuel injection pump housing as shown. 11. Install yoke (10) on spring (9) and install the pin that holds them together.12. Install spring (9) on gear (11) and install the pin that holds them together.
Woodward Governor Shown Steps 13, 18, 20, 22, 23, 28, and 29 have the guide shown for Woodward Governor only.13. Install gear (11), lock (14) and the bolts on the end of the camshaft. Bend lock (14) against the bolts.14. Install guide (12), lock (13) and the bolts on the plate assembly. Bend the tabs of lock (13) against the bolts (Woodward Governor only). 15. Install spacers (15) with their respective lifters (16) in the pump housing. If new lifters and/or pumps are to be installed, make adjustment of the fuel pump timing dimension. See SETTING THE INJECTION PUMP TIMING DIMENSION: OFF ENGINE TESTING AND ADJUSTING. 16. Install spring (17) and adapter (18) on rack (19) (Woodward Governor only). 17. Put adapter (18) and the rack in position in the fuel injection pump housing (Woodward Governor only).18. Put the rack in position in the fuel injection pump housing (hydramechanical governor only). 19. Install tool (D) on the fuel injection pump housing.
The plunger from one pump can not be installed in another pump. Do not install the pumps until the rack is in center position (centered).
20. Move adapter (18) and the rack against tool (D) to center the rack (Woodward Governor only).21. Move the rack against tool (D) to center