78028A78 Mercury GASKET SET

Table 1
Required Tools
Tool Part Number Part Description Qty
A 367-3070 Fuel Injector Installer and Removal Tooling 2
D 149-2955 Seal Protector 1
E 149-2956 Seal Installer 1
F 1U-5718 Vacuum Pump 1
169-7372 Fluid Sampling Bottle 1
4C-4057 Clear Plastic Tubing
7.92 mm (0.312 inch) OD 1
4C-4055 Clear Plastic Tubing
6.35 mm (0.250 inch) OD 1
G 9U-5470 Reamer 1
H 4C-6161 Tube Brush 1
J 9U-6862 Tapered Brush 1
K 4C-6774 Vacuum Gun Kit 1
L 4C-5027 Tap Wrench 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Evacuate as much fuel and oil as possible from the cylinder head before installing the electronic unit injector. Several evacuations may be necessary. Use Tooling (F) to remove the fuel and oil from the cylinder head.Note: Tooling (K) is available to clean loose material from the sleeve bore and the cylinder.
Inspect the electronic unit injector sleeve for damage and carbon deposits.
Clean the carbon from the sleeve, the sleeve bore, and the end of the electronic unit injector, if the electronic unit injector is being reused. Clean the carbon from the seat area that is inside the cylinder head. A fine grade of Scotch Brite material is preferred. Use Tooling (G) to clean the bore of the electronic unit injector tip. Use the Surface Reconditioning Pad to clean the carbon in the cylinder head. Use Tooling (H) to remove the carbon from the surface of the sleeve.Note: Using power tools to rotate the material should not be necessary. The carbon in the sleeve is more removable than the carbon at locations that are exposed to higher temperatures.The following procedure is the preferred method of cleaning the sleeve bore.Place a 38 mm (1.5 inch) square piece of Scotch Brite material on the end of Tooling (J). Twist Tooling (J) with Tooling (L) against the lower surface of the sleeve bore.The surface should be cleaned until the surface is smooth and shiny. The entire sleeve bore should be cleaned to remove any loose carbon particles.Note: Tooling (K) is available to clean loose material from the sleeve bore and the cylinder.
The correct procedures and tooling specifications must always be used. Failure to follow any of the procedures may result in damage, malfunction, or possible engine failure.
The O-ring seals and the backup rings must be installed in the correct orientation. Damaged seals will result in excessive oil consumption or excessive leakage under the valve cover. Use care to prevent nicks or damage to the seals.
Illustration 1 g01256103Note: Lubricate the backup rings, O-ring seals, and the bore for the electronic unit injector sleeve sparingly with clean engine oil.
Use Tooling (D) and Tooling (E) to install backup ring (4), backup ring (5), and O-ring seal (6).
Use Tooling (D) and Tooling (E) to install backup ring (9). Install O-ring seal (8).
Install O-ring seal (7).
Lubricate the O-ring seals and the backup rings on electronic unit injector (1) with clean engine oil before installation.Note: Proper installation of the electronic unit injector is very important. Damage to the upper high-pressure seals can cause excessive oil leakage under the valve cover. This may cause the engine not to start due to a low actuation pressure. Damage to the lower high-pressure seals may allow high-pressure oil to leak into the fuel supply passage. This will result in excessive oil consumption.Note: Do not hit or strike the electronic unit injector during installation. Do not use a wire brush to clean the tip of the electronic unit injector. Damage to the electronic unit injector will occur.
When you install a new electronic unit injector the E-Trim value must be programmed into the Electronic Control Module (ECM). The E-Trim value is a six digit alphanumeric code that is supplied with the data sheet that comes with the new electronic unit injectors. Use the following menu to program the E-Trim value.
ECM Summary Screen
Service Menu
Calibration
Injector Code Calibration
Illustration 2 g03029857
Use Tooling (A) to install electronic unit injector (1) in the cylinder head.
Illustration 3 g01255950
Install socket head bolts (3). Tighten socket head bolt (3) on the exhaust side of the cylinder head until the bolt is seated. Tighten socket head bolt (3) on the inlet side of the cylinder head to a torque of 16.5 1 N m (146 9 lb in).
Connect harness assembly (2) to electronic unit injector (1).
Install the plug at the rear of the cylinder head.End By:
Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".