803670 Mercury O-RING

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 9U-6198 Crankshaft Turning Tool 1
A(2) 5P-7306 Housing 1
5P-7305 Engine Turning Tool 1
B 136-4632 Timing Pin (Crankshaft) 1
268-1966 Adapter
C 364-9107 Timing Pin (Fuel Injection Pump) 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.
Illustration 1 g02482038
If necessary, use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead center. Refer to System Operation, Testing and Adjusting, "Fuel Injection Timing - Check" for the correct procedure.
Use Tooling (B) in order to lock the crankshaft so that number one piston is at top dead center.
Use Tooling (C) in order to lock fuel injection pump (13) in the correct position. Refer to System Operation, Testing and Adjusting, "Fuel Injection Timing - Check" for the correct procedure.
If necessary, install studs (21) from front housing (20). Tighten the studs to a torque of 11 N m (97 lb in).
Position a new gasket (18) onto front housing (20).
Carefully install fuel injection pump (13) to front housing (20). Ensure that front housing (20) is not damaged as the fuel injection pump is installed. Note: The fuel injection pump should be supported by hand as the bolts are installed.
Install nuts (19) to fuel injection pump (13) finger tight.
Install new bolts (22) to fuel injection pump (13). Ensure that the different length bolts are installed in to the correct position.
Tighten bolts (22) to a torque of 22 N m (195 lb in). Tighten nut (19) to a torque of 22 N m (195 lb in).
Illustration 2 g02482036
Remove Tooling (C) from fuel injection pump (9). Install a new O-ring seal (7) (not shown) to plug (8).
Install plug (8) to fuel injection pump (9). Tighten the plug to a torque of 14 N m (124 lb in).
Remove the appropriate caps in order to install fuel injection line (1). Install a new fuel injection line (1) to the fuel injection pump and to the fuel manifold. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure.
Position harness assembly (1) and bracket (5) onto the cylinder head. Loosely install bolt (4) and bolt (9) (not shown) to bracket (5).
Connected harness assembly (1) to coolant temperature sensor (2). Refer to Disassembly and Assembly, "Coolant Temperature Sensor - Remove and Install" for the correct procedure.
Install a new cable strap (3) to harness assembly (1). Note: Ensure that the new cable strap meets Original Equipment Manufactures (OEM) specifications.
Connected harness assembly (7) to the pressure sensor in the fuel manifold.
Connected harness assembly (16) to the flow control valve.
Connected harness assembly (14) to the fuel temperature sensor. Refer to Disassembly and Assembly, "Fuel Temperature Sensor - Remove and Install" for the correct procedure.
Connected harness assembly (15) to the engine oil pressure sensor. Refer to Disassembly and Assembly, "Engine Oil Pressure Sensor - Remove and Install" for the correct procedure.
Tighten bolt (4) and bolt (9) (not shown) to a torque of 9 N m (80 lb in).
Remove caps from connections for the plastic tube assemblies on fuel injection pump (13). Remove plugs from plastic tube assembly (6) and plastic tube assembly (8).
Connect plastic tube assembly (6) and plastic tube assembly (8) to fuel injection pump (13).
Illustration 3 g02612176
Remove Tooling (B) from the cylinder block.
Install a new O-ring seal (24) to plug (23). Install the plug into the cylinder block. Tighten plug (23) to a torque of 21 N m (186 lb in).
Turn the fuel supply to the ON position.
Turn the battery disconnect switch to the ON position.
Install crankcase breather canister and plastic tube assemblies. Refer to Disassembly and Assembly, "Crankcase Breather - Install" for the correct procedure.
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.
After replacement of the fuel injection pump, the fuel injection pump must be calibrated. Use the electronic service tool to perform "High Pressure Fuel Pump Calibration".