827671A 1 Mercury PILOT CHECK ASSEMBLY

Introduction
When the 228-0267 Valve GP - Modulating or the 228-0266 Coil is installed on one of the above-listed engines, the respective engine harness will need to be modified. Refer to the following instructions when installing a 228-0267 Valve GP - Modulating or a 228-0266 Coil Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts, which may cause trouble later. Inspect all parts. If any parts are worn or damaged, replace with new parts. All disassembly and all assembly procedures must be performed on a clean work surface and in a clean hydraulic area. Keep cleaned parts covered and protected at all times.Engine Harness Modifications Needed when Installing a 228-0267 Valve GP - Modulating
Illustration 1 g00948539
219-0329 Modulating Valve with Integral Connector (Old Style)
Illustration 2 g00948559
228-0267 Modulating Valve with Pigtail Connector (New Style) (1) O-ring
Illustration 3 g00948613
Turbo Wastegate Solenoid/ECM connections (Old Style and New Style)When replacing the 219-0329 Modulating Valve with the 228-0267 Valve GP - Modulating , perform the following engine harness modifications.
Disconnect the two-pin harness connector (plug) from the 219-0329 Modulating Valve .
Use wire cutters to cut the two-pin harness connector (disconnected in Step 1) from the engine harness.
Install the new 228-0267 Valve GP - Modulating .Note: Before installing the 228-0267 Valve GP - Modulating , add lubrication similar to Caterpillar 5P-3975 Rubber Lubricant to O-ring (1). If omitted, the o-ring can be damaged which could impact engine performance.
The new 228-0267 Valve GP - Modulating will have a 203 mm (8 inch) pigtail connector in place of the integral connector that is used on the 219-0329 Modulating Valve . Therefore, the engine harness cable that leads to the new 228-0267 Valve GP - Modulating will be too long. Shorten the engine harness cable to an appropriate length. Be careful not to cut the engine harness cable too short.Note: Do not attempt to remove or unmate the pigtail connector from the 228-0267 Valve GP - Modulating . Refer to Illustration 2.
After shortening the engine harness cable, peel back the engine harness cable braiding approximately 50 mm (2 inch). Crimp a 180-9339 Connector Pin on each of the two harness wires.Note: Prior to crimping, make sure that enough insulation has been removed from each wire to ensure a good connection.
Insert the white wire (with crimped 180-9339 Connector Pin ) into Location 1 of the 151-9272 Receptacle Kit . Insert the black wire (with crimped 180-9339 Connector Pin ) into Location 2 of the 151-9272 Receptacle Kit . Refer to Illustration 3.
Use a 3E-3665 Wedge to secure the pins in the connector.Note: The 3E-3665 Wedge is included in the 151-9272 Receptacle Kit and cannot be purchased separately.
Use shrinkable tubing or tie-wraps to secure the harness braiding.
Use the existing ladder clips to support the engine wire harness. A tie point to the ladder clip on either side of the two-pin connector is required.Engine Harness Modifications Needed when Installing a 228-0266 Coil
The 228-0266 Coil replaces the 155-4426 Coil .
Illustration 4 g00948606
155-4426 Coil with Integral Connector (Old Style)
Illustration 5 g00948609
228-0266 Coil (New Style)
Disconnect the two-pin harness connector (plug) from the 155-4426 Coil .
Use wire cutters to cut the two-pin harness connector (disconnected in Step 1) from the engine harness.
Install the new 228-0266 Coil .
The new 228-0266 Coil will have a 203 mm (8 inch) pigtail connector in place of the integral connector that is used on the 155-4426 Coil . Therefore, the engine harness cable that leads to the new 228-0266 Coil will be too long. Shorten the engine harness cable to an appropriate length. Be careful not to cut the engine harness cable too short.Note: Do not attempt to remove or unmate the pigtail connector from the 228-0266 Coil . Refer to Illustration 5.
After shortening the engine harness cable, peel back the engine harness cable braiding approximately 50 mm (2 inch). Crimp a 180-9339 Connector Pin on each of the two harness wires.Note: Prior to crimping, make sure that enough insulation has been removed from each wire to ensure a good connection.
Insert the white wire (with crimped 180-9339 Connector Pin ) into Location 1 of the 151-9272 Receptacle Kit . Insert the black wire (with crimped 180-9339 Connector Pin ) into Location 2 of the 151-9272 Receptacle Kit . Refer to Illustration 3.
Use a 3E-3665 Wedge to secure the pins in the connector.Note: The 3E-3665 Wedge is included in the 151-9272 Receptacle Kit and cannot be purchased separately.
Use shrinkable tubing or tie-wraps to secure the harness braiding.
Use the existing ladder clips to support the engine wire harness. A tie point to the ladder clip on either side of the two-pin connector is required.