16911T Mercury COVER, Top

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 9U-6198 Crankshaft Turning Tool 1
A(2) 9U-7336 Housing 1
5P-7305 Engine Turning Tool 1
B 136-4632 Engine Timing Pin 1
268-1966 Adaptor 1
C 364-9107 Fuel Injection Pump Timing Pin 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.Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
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.
Ensure that wiring harness are correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness convoluting.
Illustration 1 g01967538
If necessary, use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Fuel Injection Timing - Check". Use Tooling (B) in order to lock the crankshaft so that number one piston is at top dead center position.
If necessary, install Tooling (C) in order to lock the fuel injection pump in the correct position.
Position a new gasket (17) (not shown) onto front housing (16).
Position bolt (15) and spacer (14) onto fuel injection pump (10).
Carefully install fuel injection pump (10) to front housing (16). Ensure that the bore in front housing (16) is not damaged as the fuel injection pump is installed. Note: The fuel injection pump should be supported by hand as the nuts and bolts are installed.
Tighten bolt (15) for fuel injection pump (10) finger tight.
Install nut (13) to fuel injection pump (10) finger tight.
Install new bolts (17) to fuel injection pump (10) finger tight.
Tighten bolts (17) and bolts (15) to a torque of 22 N m (195 lb in). Tighten nut (13) to a torque of 22 N m (195 lb in).
Illustration 2 g01967536
Remove Tooling (C) from fuel injection pump (10). Install a new O-ring seal (9) (not shown) to plug (8).
Remove Tooling (B) from the cylinder block. Install a new O-ring seal to the plug for the cylinder block. Install the plug to the cylinder block. Tighten the plug to a torque of 21 N m (186 lb in).
Install plug (8) to fuel injection pump (10). Tighten the plug to a torque of 14 N m (124 lb in).
Remove the appropriate caps in order to install fuel injection line (11). Install a new fuel injection line (11) to the fuel injection pump and to the fuel manifold. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure.
Connect harness assembly (1) to the sensor on fuel injection pump (10).
Connect harness assembly (3) from the solenoid on fuel injection pump (10).
Remove the appropriate plugs and caps in order to install plastic tube assembly (2), plastic tube assembly (4), and plastic tube assembly (5).
Connect plastic tube assembly (2), plastic tube assembly (4), and plastic tube assembly (5) to fuel injection pump (10).
Remove the appropriate plugs and caps in order to install hose assembly (12).
Install a new sealing washer (6) to banjo bolt (7). Install the banjo bolt to hose assembly (12). Install the remaining new sealing washer (6) to banjo bolt (7) after the banjo bolt is installed to the hose assembly.
Install hose assembly (12) to fuel injection pump (10) and tighten banjo bolt (7) finger tight.
Tighten banjo bolt (7) to a torque of 22 N m (195 lb in).
If necessary, install the fuel priming pump. Refer to Disassembly and Assembly, "Fuel Priming Pump - Remove and Install".
If necessary, install the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install" for the correct procedure.
Replace the filters for primary fuel system. Refer to Operation and Maintenance Manual, "Fuel System Primary (Water Separator) Element - Replace" for the correct procedure.
Replace the filters for secondary fuel system. Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure.
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 Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure. End By:
After replacement of the fuel injection pump, the fuel injection pump requires a high-pressure fuel pump calibration procedure to be performed. Refer to Troubleshooting, "Fuel Rail Pressure Problem" for the correct procedure.