882512 Mercruiser COVER, Dust

Table 1
Required Tools
Part Number Part Name Qty
5P-4150 Tester Group 1
5P-7448 Adapter 1
6V-2170 Tube Assembly 1
8S-2270 Fuel Collector 1
1U-8857 Extension 1
6V-6068 SAE J-967 Calibration Fluid 1
Illustration 1 g00376593
Fuel injection nozzle
(1) Connection for the fuel return line
(2) Nut for the clamp
(3) Clamp
(4) Connection for the fuel supply line
(5) Spacer
(6) O-ring
(7) Fuel injection nozzle
(8) Seat washer
(9) Hole for the fuel injection nozzle
(10) Threaded hole for the spacer
Start the engine and run the engine at low idle.
Loosen the nut for fuel supply line (4) at each fuel injection nozzle. Listen for the low idle to decrease at each cylinder. Also, listen for the low idle to become rough at each cylinder.
The fuel injection nozzle may be damaged if the items that follow occur:
Engine rpm does not decrease.
The engine continues to run properly.Remove the fuel injection nozzle from the engine cylinder head for additional testing.Note: If leakage at the nut for fuel supply line (4) occurs, make sure that the fuel supply line and the nut for the fuel supply line are correctly aligned with the inlet connection of the fuel injection nozzle. Do not tighten the nut for the fuel supply line on the high pressure fuel line more than the recommended torque. If the nut is tightened more, the fuel line may become restricted or the threads of the fuel injection nozzle and the nut may be damaged.Cleaning Of Fuel Injection Nozzles
Before a fuel injection nozzle is tested, remove any loose carbon from the tip of the fuel injection nozzle. Do not use abrasive material or a wire brush in order to clean the nozzle.The fuel injection nozzle is not a serviceable part. Disassembling or adjusting the nozzle will violate the standards for emissions.Note: Extra care should be used in handling the fuel injection nozzle in order to prevent damage to the nozzle tip. A scratch or a burr could cause needle leakage or spray distortion. Dirt that is in the orifices of the nozzle tip can damage engine components. Dirt can also cause spray distortion.Pressure Test
Ensure that you wear eye protection at all times during testing. When fuel injection nozzles are tested, test fluids travel through the orifices of the nozzle tip with high pressure. Under this amount of pressure, the test fluid can pierce the skin and cause serious injury to the operator. Always keep the tip of the fuel injection nozzle pointed away from the operator and into the fuel collector and extension.
Illustration 2 g00398982
Pressure test the fuel injection nozzle by using the 5P-4150 Nozzle Testing Group.
(11) 5P-7448 Adapter
(12) Fuel injection nozzle
(13) 5P-4721 Tube
(14) 1U-8857 Extension
(15) 8S-2270 Fuel Collector
(16) 8T-5313 Filter
Do not use dirty test fluids when you test fuel injection nozzles. Also, do not test fuel injection nozzles unless you have the correct service tools.The use of dirty test fluids and the use of incorrect service tools will result in damage to fuel injection nozzles.
Connect fuel injection nozzle (12) to the tooling that is shown in Illustration 2.The spray from the fuel injection nozzle must be directed into 1U-8857 Extension (14) and 8S-2270 Fuel Collector (15).Refer to the table in the Specifications Module, "Fuel Injection Nozzles" topic for the correct pressure settings. If the opening pressure is not within the range of the setting which is given in the table, the fuel injection nozzle must be replaced.Use clean 6V-6068 Calibration Fluid when the fuel injection nozzles are tested. The calibration fluid is similar to SAE J-967 (ISO 4113) oil.
Close the gauge protector valve. Close the shutoff valve. Open the pump isolator valve. Flush the fuel injection nozzle by operating the nozzle tester. Operate the nozzle tester for 10 to 15 strokes at a rate of approximately sixty strokes per minute.
Open the gauge protector valve. Slowly increase the pressure until the valve in the fuel injection nozzle opens. Note the highest pressure indication on the dial indicator before the pointer moves to 0 kPa (0 psi). This highest pressure indication is the opening pressure of the fuel injection nozzle. The opening pressure will happen when valve needle rises from the nozzle seat.Refer to the table in the Specifications Module, "Fuel Injection Nozzles" topic for correct pressure settings. If the opening pressure is not within the range of the setting that is given in the table, the fuel injection nozzle must be replaced.Back Leakage Test
Connect fuel injection nozzle (12) to the tooling that is shown in Illustration 2.Position the fuel injection nozzle so that the direction of the fuel spray is into 1U-8857 Extension (14) and 8S-2270 Fuel Collector (15).
Pump the pressure to about 1030 kPa (150 psi) below the opening pressure of the fuel injection nozzle. Refer to the Specifications Module, "Fuel Injection Nozzles" topic for the correct setting of the opening pressure. Release the handle. When the pressure begins to decrease, note the time that is required for the pressure to decrease