42600A 3 Mercruiser CONTROLLER ASSEMBLY

Table 1
Required Tools
Tool Part Number Part Description Qty
B - Crankshaft Turning Tool 1
C 136-4632 Timing Pin Camshaft 1
592-9030 Adaptor 1
D 364-9107 Timing Pin (Fuel Injection Pump) 1
522-2016 Adapter 1
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High-Pressure Fuel Lines" for safety information.Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Ensure that all components of the fuel injection pump are free from damage and wear. Replace any component that is worn or damaged.
If necessary, install the fuel injection pump gear. Refer to Disassembly and Assembly, "Fuel Injection Pump Gear - Install" for the correct procedure.
Illustration 1 g06324889
If necessary, use Tooling (B) to rotate the crankshaft so that number one piston is at top dead center. Refer to System Operation, Testing and Adjusting, "Fuel Injection Timing - Check" for the correct procedure.
Illustration 2 g06326934
If necessary, use Tooling (C) in position (X) to ensure that the camshaft is locked with number one piston at top dead center.Note: Do not use excessive force to install Tooling (C). Do not use Tooling (C) to hold the crankshaft during repairs.
Install a new O-ring seal (13) (not shown) to fuel injection pump (6). Ensure that the O-ring seal is correctly installed onto the fuel injection pump.
Install Tooling (D) to fuel injection pump (6), in Position (Y).
Carefully install fuel injection pump (6) to cylinder block (7). Ensure that the fuel injection pump gear engages correctly as the fuel injection pump is installed into the cylinder block.
Install new bolts (10) to fuel injection pump (6). Support the fuel injection pump as the bolts are installed.
Tighten bolts (10) to a torque of 22 N m (195 lb in).
Remove tooling (D).
Install a new O-ring seal (12) (not shown) to plug (11). Install the plug to fuel injection pump (6) and tighten the plug to a torque of 14 N m (124 lb in).
Remove tooling (C).
Install a new O-ring seal (9) (not shown) to plug (8). Install the plug to cylinder block (7) and tighten the plug to a torque of 15 N m (133 lb in).
Illustration 3 g06474098
Install a new fuel injection line (1) to fuel injection pump (6) and the fuel manifold. Refer to Disassembly and Assembly, Fuel Injection Lines - Install for the correct procedure.
Connect harness assembly (2) to flow control valve (3).
Connect harness assembly (4) to fuel temperature sensor (5).
If necessary, replace the filters for the primary fuel system. Refer to Operation and Maintenance Manual, "Fuel System Primary (Water Separator) Element - Replace" for the correct procedure.
If necessary, replace the filters for the secondary fuel system. Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure.
Turn the battery disconnect switch to the ON position.End By:
Install the low-pressure fuel system. Refer to Disassembly and Assembly, Fuel Pressure Regulator - Remove and Install for the correct procedure.
Install the air inlet elbow. Refer to Disassembly and Assembly, Air Inlet Elbow - Remove and Install for the correct procedure.
Install the Exhaust cooler (NRS). Refer to Disassembly and Assembly, Exhaust Cooler (NRS) - Remove and Install for the correct procedure.
Refill with coolant. Refer to Operation and Maintenance Manual, Coolant - Change for the correct procedure.
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, Fuel System - Prime for the correct procedure.
After replacement of the fuel injection pump, the fuel injection pump must be calibrated. Use the electronic service tool to perform "High Pressure Fuel Pump Calibration".