60484 Mercury GEAR HOUSING ASS'Y, COMP. (MERC 1500XS)

Table 1
Required Tools
Tool Part Number Part Description Qty
A 370-8376 Capping Kit 1
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 battery disconnect switch to the OFF position.
Turn the fuel supply to the OFF position.
Illustration 1 g03466436
Illustration 2 g03466476
Cut all cable straps that attach the wiring harness assemblies to electronic control module (6). Note: Note position of cable straps that attach the wiring harness assemblies to the electronic control module.
Remove bolt (2). Loosen allen head bolt (3) that secures engine wiring harness assembly (4) to electronic control module (6). Disconnect the engine wiring harness assembly from the electronic control module.
Remove bolt (7). Loosen allen head bolt (5) that secures engine wiring harness assembly (9) to electronic control module (6). Disconnect the Original Equipment Manufactures (OEM) wiring harness assembly from the electronic control module.
Position harness assembly (9) and harness assembly (4) away from electronic control module (6).
Make temporary identification marks on fuel line (1) and fuel line (8) in order to show the correct position of the fuel lines.
Place a suitable container below electronic control module (6) in order to catch any fuel that might be spilled.
Disconnect fuel line (1) and remove the fuel line from the fuel line clips. Use Tooling (A) to plug fuel lines (1). Position the fuel line away from the electronic control module.
Use Tooling (A) to cap connection (10) on the electronic control module.
Remove fuel line (8) and drain the fuel from electronic control module (6). Use Tooling (A) to plug fuel lines (8).
Use Tooling (A) to cap connection (11) on the electronic control module.
Illustration 3 g03466496
Loosen bolts (16) for electronic control module (6).
Remove bolts (16) and remove washers (14) and washer (15). Take care to prevent damage to ground connection (13). Note: Support the weight of the electronic control module as the remaining bolts are removed.
Remove bracket (12) and remove electronic control module (6). Note: Note the orientation of the electronic control module.
If necessary, remove isolation mounts (17), isolation mounts (18), and limit sleeves (19) from electronic control module (6).
Illustration 4 g03466559
If necessary, follow Step 17.a through Step 17.b in order to remove connections from electronic control module (6).
Remove connection (10) and remove O-ring seal (20) (not shown). Use Tooling (A) to cap connection (10) and plug electronic control module (6).
Remove connection (11) and remove O-ring seal (21) (not shown). Use Tooling (A) to cap connection (11) and plug electronic control module (6). Installation Procedure
If a replacement electronic control module is installed, the module must be programmed with the correct information. Refer to Troubleshooting Guide, "Replacing the ECM" and refer to Troubleshooting Guide, "Flash Programming" for the correct procedure.
Ensure that the electronic control module is clean and free from damage. If necessary, replace the electronic control module.
Illustration 5 g03466559
If necessary, follow Step 3.a through Step 3.d in order to install connections to electronic control module (6).
Remove the cap from connection (10). Install a new O-ring seal (20) (not shown) to the connection.
Remove the cap from connection (11). Install a new O-ring seal (21) (not shown) to the connection.
Remove the plugs from electronic control module (6).
Install connection (10) and connection (11) to electronic control module (6). Tighten the connections to a torque of 18 N m (159 lb in).
Illustration 6 g03466496
If necessary, install isolation mounts (17), isolation mounts (18), and limit sleeves (19) to electronic control module (6).
Install washers (14) and washers (15) to bolts (16). Ensure that ground strap (13) for the electronic control module is clamped between washer (15) and washer (14).
Position electronic control module (6) on the mounting bracket. Tighten bolts (16) hand tight. Note: Ensure that the electronic control module is correctly oriented.
Position bracket (12) onto electronic control module (6). Install remaining bolt (16) to bracket (12).
Tighten bolts (16) to a torque of 22 N m (195 lb in). Note: Ensure that the ground strap is not strained as the bolt is tightened.
Illustration 7 g03466476