861523A11 Mercruiser COUPLER ASSEMBLY, Engine

Ensure that the wiring harness assembly is correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness and the convoluting.
The Electronic Control Module (ECM) can be a fuel cooled ECM or air cooled ECM. The installation procedure is similar for a fuel cooled ECM or air cooled ECM.
If a replacement ECM is installed, the replacement ECM must be programmed with the correct information. Refer to Troubleshooting Guide, "Replacing the ECM" and refer to Troubleshooting Guide, "Flash Programming" for the correct procedure.
Ensure that the electronic control module is clean and free from damage. If necessary, replace the electronic control module.
Illustration 1 g03738902
Typical example
If necessary, install spacers (48) to cylinder block (49). Tighten the spacers to a torque of 44 N m (32 lb ft).
Illustration 2 g03738901
Fuel cooled ECM
If necessary, follow Step 5.a through Step 5.d in order to assemble ECM (28).
Remove caps from connection (41). Install new O-ring seal (42) to the connection.
Remove caps from connection (44). Install a new O-ring seal (43) to the connection.
Remove plugs from ECM (28). Install connection (41) and connection (44) to the ECM. Tighten the connections to a torque of 18 N m (159 lb in).
Install isolation mount (45), isolation mount (47), and limit sleeves (46) to ECM (28).
Illustration 3 g03738900
Typical example
Position bracket (32) onto ECM (28). Ensure that the bracket is correctly orientated.
Position bracket (32) and ECM (28) onto the cylinder block. Support the weight of the ECM as the bolts are installed. Note: Ensure that the fuel injection line is not damaged during the installation of the bracket.
Install bolts (38) and washer (39) (not shown) to bracket (32) and to ECM (28). Ensure that earth strap (40) is correctly positioned between the bolts and the washers. Hand tighten the bolts.
Tighten bolts (38) to a torque of 22 N m (195 lb in).
Install spacer (30) and bolt (29) to valve (31). Tighten the bolt to a torque of 9 N m (80 lb in).
Remove caps connection on valve (31) and the plastic tube assembly. Connect the plastic tube assembly to valve (31)
Install plastic tube assembly (33) and plastic tube assembly (34) to clips (35).
Remove caps connections on the ECM for plastic tube assemblies. Remove plugs from plastic tube assembly (37) and plastic tube assembly (36).
Connect plastic tube assembly (37) and plastic tube assembly (36) to connections on ECM (28).
Illustration 4 g03738899
Position the OEM harness assembly (27) onto ECM (28).
Tighten the allen head bolt (23) that secures OEM plug (21) for the OEM harness assembly (27) to ECM (28). Ensure that the OEM wiring harness is correctly routed. Note: Care must be taken in order to avoid damage to the connector pins during installation of the harness assembly.
Install bolt (25) to OEM plug (21). Hand tighten the bolt.
Tighten allen head bolt (23) to a torque of 6 N m (53 lb in). Tighten bolt (25) to a torque of 6.5 N m (59 lb in).
Position engine harness assembly (26) onto ECM (28). Ensure that the engine wiring harness is correctly routed.
Tighten the allen head bolt (22) that secures ECM plug (20) for engine harness assembly (26) to ECM (28). Note: Care must be taken in order to avoid damage to the connector pins during installation of the harness assembly.
Install bolt (24) to ECM plug (20). Hand tighten the bolt.
Tighten allen head bolt (22) to a torque of 6 N m (53 lb in). Tighten bolt (24) to a torque of 6.5 N m (59 lb in).
Install new cable straps (19) to engine harness assembly. Note: Ensure that the cable straps meet OEM specifications.
Illustration 5 g03738863
Typical example
Remove the plug from cylinder head and to the cap from tube assembly (12). Install a new O-ring seal (18) (not shown) to the tube assembly.
Install tube assembly (12) to the bracket and the cylinder head. Install bolt (13) to the tube assembly hand tight.
Use a suitable tool in Position (X) in order to hold tube assembly (12) as nut (15) is tightened hand tight.
Tighten bolt (13) to a torque of 22 N m (195 lb in).
Use the suitable tool to hold tube assembly (12) in Position (X). Tighten nut (15) to a torque of 28 N m (248 lb in). Ensure that the tube assembly is not strained as the nut is tightened.
Remove the plug from plastic tube assemblies and the cap from tube assembly (12). Connect plastic tube assembly (11) and plastic tube assembly (14) to the tube assembly
Remove the plug from hose assembly (16) and remove the cap from tube assembly (12).
Install a new O-ring seal (17) (not shown). Ensure that the O-ring seal is correctly seated into the recess of the tube assembly.
Connect hose assembly (16) from connection on tube assembly (13) hand tight.
Use the suitable tool to hold tube assembly (12) in Position (X). Tighten the nut for hose assembly to a torque of 43 N m (32 lb ft).
Illustration 6 g03738326
Typical example
Illustration 7 g03738325
Typical example