808682A97 Mercury DECAL SET

Table 1
Required Tools
Tool Part Number Part Description Qty
A 5F-4764 Pry Bar 1 Start By:
Remove the rocker shaft assembly.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01130566
Disconnect harness assembly (2) from electronic unit injector (5).
Remove bolt (1) and electronic unit injector clamp (3).
Remove plug (4) from the cylinder head.
Place an identification mark on the electronic unit injector for installation purposes. Each electronic unit injector must be reinstalled in the original location in the cylinder head.
Illustration 2 g01130569
Use Tooling (A) to remove electronic unit injector (5) from the cylinder head.
Remove O-ring seal (6) and O-ring seal (7) from the electronic unit injector. Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
B 9U-6862 Tapered Brush 1
C 4C-5027 Tap Wrench 1
D 4C-6774 Vacuum Gun Kit 1
E 1P-0808 Multipurpose Grease -
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 3 g01130613
Use Tooling (B) to clean the bore for the electronic unit injector in the cylinder head. Hold Tooling (B) with Tooling (C). Rotate Tooling (B) against Surface (X) of the bore. Continue cleaning until Surface (X) is smooth and shiny.
Use Tooling (D) to remove the fuel from the cylinder. Evacuate as much fuel as possible from the cylinder before installing the electronic unit injector. Several evacuations may be necessary.
Illustration 4 g01130615
Install O-ring seal (6) and O-ring seal (7) on the electronic unit injector.
Apply Tooling (E) to the bore of the cylinder head for the electronic unit injector.
When an electronic unit injector is replaced, the new electronic injector code must be programmed into the engine's personality module software by using the calibration menu on the Electronic Service Tool. If the new electronic injector code is not entered, the characteristics of the previous electronic unit injector is assumed.If it is not possible to immediately reprogram the electronic injector code into the personality module software, the engine will not be severely harmed. The new electronic injector code should be reprogrammed as quickly as possible in order to optimize engine performance.
Position electronic unit injector (5) into the original location in the cylinder head. Center the solenoid between the valve springs. Press the electronic unit injector into the cylinder head. Do not strike the electronic unit injector.
Illustration 5 g01130566
Install plug (4) in the cylinder head.
Install electronic unit injector clamp (3) and bolt (1). Tighten bolt (1) in order to seat electronic unit injector (5) in the cylinder head. Do not strike the electronic unit injector. Tighten bolt (1) to a torque of 65 7 N m (48 5 lb ft).
Connect harness assembly (2). Tighten the terminal nuts to a torque of 2.5 0.25 N m (22 2 lb in). End By:
Install the rocker shaft assembly.