860235A03 Mercruiser MANIFOLD ASSEMBLY, Exhaust

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
B     276-1216     Injector Pipe Nut Tool     1    
C     367-2771     Wrench     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.
Note: The following procedure should be adopted in order to install the fuel injection lines when the electronic unit injectors or the fuel manifold have not been removed. If the electronic unit injectors or the fuel manifold have been removed, refer to Disassembly and Assembly, "Electronic Unit Injector - Install" and Disassembly and Assembly, "Fuel Manifold - Install" for more information.
Illustration 1 g02481080
Remove plugs from fuel manifold (5) and fuel injection pump (23) .
Remove the caps from new fuel injection line (24) .
Position fuel injection line (24) onto fuel injection pump (23) and fuel manifold (5) . Loosely install nuts for the fuel injection line onto the fuel manifold and the fuel injection pump.
Install bolt (20) to the tube clip finger tight.
Install bolt (21) and spacer (22) to the tube clip finger tight.
Use Tooling (C) to tighten the nuts on fuel injection line (24) to a torque of 40 N m (30 lb ft).
Tighten bolt (20) and bolt (21) to a torque of 10 N m (89 lb in).Note: Ensure that fuel injection lines do not contact any other engine component.
Illustration 2 g02625818
Position bracket (18) and the harness assembly onto the fuel injection pump.
Install bolt (16) and bolt (19) (not shown) to bracket (18) . Tighten the bolt to a torque of 9 N m (80 lb in).
Connect harness assembly (14) to coolant temperature sensor (12) . Slide locking tab (13) into the locked position.
Connect harness assembly (17) to fuel pressure sensor.
Install new cable strap (15) .Note: Ensure that the cable strap meets Original Equipment Manufactures (OEM) specification.
Illustration 3 g02481216
Illustration 4 g02481081
Illustration 5 g02625722
Install new seals (3) to the electronic unit injector and cylinder head (6) . Ensure that the flange on the seal is flush with the cylinder head.
Remove the caps from the port of the electronic unit injector and from the appropriate port in fuel manifold (5) .
Loosely connect the nuts at both ends of fuel injection line (1) and fuel injection line (4) , to the electronic unit injector and to the appropriate port in fuel manifold (5) . Ensure that the ends of the fuel injection line are correctly seated in the electronic unit injector and in the fuel manifold.
Install bracket (10) and isolator (11) . Position isolator (9) and clamp plate (8) .
Use a suitable tool in order to install clamp plate (8) to bracket (10) .
Install bolt (2) finger tight.
Use Tooling (B) to tighten the nuts on fuel injection line (1) and fuel injection line (4) to a torque of 40 N m (30 lb ft). Ensure that the dust seal is seated correctly against the seal.
Tighten bolt (2) to a torque of 10 N m (89 lb in).
Follow Step 13 through Step 20 in order to install the remaining fuel injection lines.
Turn the fuel supply to the ON position.
Turn the battery disconnect switch to the ON position.
Remove the air from the fuel system. Refer to Operations and Maintenance Manual, "Fuel System - Prime" for the correct procedure.End By:
Install the inlet air control (NRS Induction Mixer). Refer to Disassembly and Assembly, "Inlet Air Control (NRS Induction Mixer) - Install" for the correct procedure.
Install secondary fuel filter assembly. Refer to Disassembly and Assembly, "Fuel Filter Base (Single Secondary Fuel Filter) - Remove and Install" for the correct procedure.
Install water separator and fuel filter (Primary). Refer to Disassembly and Assembly, "Water Separator and Fuel Filter (Primary) - Remove and Install" for the correct procedure.
Install crankcase breather canister and plastic tube assemblies. Refer to Disassembly and Assembly, "Crankcase Breather - Remove" for the correct procedure.