42682 Mercruiser WELCH PLUG (1-1/4 inch O.D.)

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 9U-6198 Crankshaft Turning Tool 1
A(2) 5P-7306 Housing 1
5P-7305 Engine Turning Tool 1
B 136-4632 Timing Pin
(Crankshaft) 1
268-1966 Adapter 1
C 364-9107 Timing Pin
(Fuel Injection Pump) 1
D 370-8376 Plugging Kit 1
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.Start By:
Remove crankcase breather canister and plastic tube assemblies. Refer to Disassembly and Assembly, "Crankcase Breather - Remove" for the correct procedure.Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
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.
Turn the fuel supply to the OFF position.
Turn the battery disconnect switch to the OFF position.
Illustration 1 g06187954
Remove plug (12) and remove O-ring seal (11) (not shown) from fuel injection pump (1).
Install Tooling (C) to fuel injection pump (1) in Position (X).
Use Tooling (A) 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.
Use Tooling (B) to ensure that the crankshaft is locked with number one piston at top dead center.
Disconnected harness assembly (5) from flow control valve (6).
Disconnected harness assembly (7) from fuel temperature sensor (10).
Disconnected harness assembly (8) from the engine oil pressure sensor (9).
Unclip tube assembly (4) from bracket (3).
Remove bolt (2) and remove bracket (3) from the cylinder head.
Clean fuel injection pump (1) and the area around the fuel injection pump. Ensure that the area is free from contamination before beginning disassembly.
Place a suitable container below fuel injection pump (1) to catch any fuel that might be spilled.
Illustration 2 g06188039
Disconnect plastic tube assembly (4) and plastic tube assembly (14) from the fuel injection pump. Use Tooling (D) to plug the plastic tube assemblies. Cap the connections for plastic tube assemblies on the fuel injection pump.
Remove fuel injection line (13) that connects the fuel injection pump to the fuel manifold. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove" for the correct procedure.
Use Tooling (D) to plug the open ports in the fuel injection pump and in the fuel manifold. Discard fuel injection line (13).
Remove nuts (16) from studs (15) and bolts (19) from the fuel injection pump . Note position of the different length bolts.Note: The fuel injection pump should be supported by hand as the bolts are removed.
Carefully remove the fuel injection pump from front housing (17). Ensure that the bore in the front housing is not damaged as the fuel injection pump is removed.
Remove gasket (18) (not shown).
If necessary, remove studs (15) from front housing (17).