823042039 Mercury BOLT

References
Safety
Before starting the procedure of mounting the fuel injection pump and tooling onto the test stand, make sure the Emergency Stop button is pushed IN. Another recommended safety precaution is to turn the power OFF and lock-out the electrical box. An SEHS7332 "Warning: Do Not Operate" tag should also be placed on the electrical box.
Illustration 1. Place Tag On Electrical Box When Working On Or Around Rotating PartsNomenclature
135-2916 Adapter Group
The parts in Charts A, B, and C are part of the 135-2916 Adapter Group and required to test 3406B, 3406C, and 3406 PEEC Engines.
Illustration 2. 135-2916 Adapter Group (front mounting hardware). Refer to Chart A for item identification.
Illustration 3. 135-2916 Adapter Group (rear mounting hardware). Refer to Chart B for item identification.
Illustration 4. 135-2916 Adapter Group (injection pump hardware). Refer to Chart C for item identification.
Illustration 5. Front and rear support clamping hardware. (Common to many mounting groups.) Drive Adapters
The drive adapters listed in Chart E are used on the original 25 mm (1.0 in) 4C-8723 Jaw Assembly or the new 4C-8192 Heavy-Duty Coupling Group. Refer to the Installation section and the charts below to determine the correct adapter. Refer to Charts F and G and Illustrations 6 and 7 for a list of drive adapters and associated hardware.
Illustration 6. Drive adapters with 25 mm (1.0 in) shaft diameters for use with 4C-8723 Jaw Assembly. Refer to Chart F for item identification.
Illustration 7. Drive adapters for use with 4C-8192 Heavy-Duty Coupling and Torque Tube. Refer to Chart G for item identification. Required Pump Testing Tooling
Illustration 8. Rack preload and positioning assembly for 3406 PEEC Engines. Refer to Chart H for item identification.
Illustration 9. Injection Pump Testing Tooling. Refer to Chart I for item identification.
Illustration 10. TMI screen. Refer to procedure below to obtain pump specifications.TMI Specifications
Delivery specifications are published "on-line" in TMI. To access these specifications, use the following procedure. For additional information on TMI, refer to NEHS0594.Finding Test Specification Data When Engine Arrangement Level, Pump Group, and Governor Group Part Numbers Are Known
The Step numbers below correspond to the item callouts in Illustration 11.1. Type "GNK401". The cursor will automatically move to the next field.2. Type in "12". Press "Enter".3. Type in the pump part number in the "ARRG/GP NUMBER" field and press "Enter". This example shows a 6I-3060 part number.4. Find the correct line number.5. Type in the line number; "011". Press "Enter".6. Scroll through the data using the "Enter" key.Installation
This procedure was written using the 4C-8192 Heavy-Duty Coupling Group, which is the preferred coupling. Refer to Charts E, F, and G for the correct adapter and associated hardware depending on which coupling group is used on the test stand.1. Push the Emergency Stop button IN.
Make sure the puller hole in the plug is facing out when the plug is installed. If the puller hole is facing in, the plug and possibly the fuel injection pump will be damaged when the plug is removed.
Illustration 11. Install Plug. Example of 8T-2849 Plug.
(A) Hole. (B) Threaded puller hole. (C) Cross-hole.2. Install one of three plugs into the injection pump cam shaft. Install plug into hole (A) with the threaded puller hole facing out. The plug must be installed beyond hole (C).a. Use the 8T-2848 Plug for 8N-9681 and 2W-5242 Fuel Injection Pumps. Make sure the 4W-4616 Quad Ring Seal is on the plug before installation.b. Use the 8T-2849 Plug for almost all other fuel injection pumps that do not use the 8T-2849 Plug. Make sure the 4W-0435 Quad Ring Seal is on the plug before installation.c. Use the 7H-2069 Bolt for all pumps having a threaded hole.3. Install the drive adapter onto the camshaft of the fuel injection pump. Refer to Chart E to determine the correct adapter.4. Install four OL-1143 Bolts and finger tighten.5. Install the 9U-5297 Transfer Pump Opening Cover over the opening for the transfer pump (a gasket must be made to properly seal the opening). Use two 2A-0762 Bolts to attach the cover and completely tighten the bolts.6. Attach the front adapter group and related parts to the pump, as shown in Illustration 2. Bolt the pump to the front adapter group using four, 3/8-16, 1D-4717 Nuts. Tighten the nuts finger tight.
Illustration 12. Install O-rings (1) and (2)7. Install 1S-0004 O-ring Seal (1) and 8S-5953 O-ring Seal (2) into the O-ring grooves.
Illustration 13. Install Rear Support Assembly
(1) OS-1591 Bolt. (2) 3B-1915 Bolt.8. Install the rear support assembly and related parts onto the pump, as shown in Illustration 3. Install two bolts (1) and (2) and finger tighten from underneath the pump.9. Install the pump assembly (front and rear supports attached) onto the test stand rails with the appropriate hardware.
Illustration 14. Insert Timing Pin (1) To Tighten Adapter Bolts10. Tighten the four drive adapter bolts to 44 7 N m (32 5 lb ft). Use timing pin (1) to keep the camshaft from rotating when tightening the bolts.11. Attach the drive adapter (pump end) to the heavy-duty coupling (test stand end). a. Align the bolt holes of the torque tube on heavy-duty coupling with the threaded holes in the drive adapter.b. Slide the pump forward and engage the drive adapter with the heavy-duty coupling.c. Install six bolts and finger tighten.
If the flex plates are operated under axial load (pushed in or pulled out) the flex plates will be damaged.
d. Position the