40011 67 Mercury SCREW, (M3.5 x 16) Stainless Steel

The following background information is related to this procedure:Injector codes are seven digit alphanumeric codes that are supplied with each injector. The code is printed on each injector. The code is used by the ECM to balance the performance of the injectors.Refer to Troubleshooting, "Injector Code - Calibrate" for further information.
Illustration 1 g02738616
Typical example of an electronic unit injector
(1) Location of the injector code
Table 2
Troubleshooting Test Steps Values Results
1. Check That the Correct Injector Codes Have Been Programmed
A. Check that the injector codes that have been programmed match the codes that are on the injectors.
Refer to Troubleshooting, "Injector Code - Calibrate".
Injector codes
Result: The injector codes are correct.
Proceed to Test Step 2.
Result: One or more of the injector codes is incorrect.
Repair: Use the electronic service tool to program the correct injector codes.
Refer to Troubleshooting, "Injector Code - Calibrate".
Proceed to Test Step 2.
2. Check for Active Diagnostic Codes
A. Connect the electronic service tool to the diagnostic connector. Refer to Troubleshooting, "Electronic Service Tools".
B. Turn the keyswitch to the ON position.
C. Use the electronic service tool to check for active diagnostic codes.
Diagnostic codes
Result: One of the following diagnostic codes is active:
651-2
652-2
653-2
654-2
Note: The ECM will learn the correct values in order to clear these diagnostic codes. Only continue with this procedure if the code has been active for at least 2 hours after the injector code was programmed.
Proceed to Test Step 3.
Result: One of the following diagnostic codes is active:
630-2
651-13
652-13
653-13
654-13
Proceed to Test Step 3.
3. Re-Flash the ECM
A. Reflash the ECM. Refer to Troubleshooting, "ECM Software - Install".
B. Ensure that all of the injector codes are programmed. Refer to Troubleshooting, "Injector Code - Calibrate".
C. Use the electronic service tool to clear all active diagnostic codes.
D. Start the engine.
E. Use the electronic service tool to check for active diagnostic codes.
Diagnostic codes
Result: One of the diagnostic codes listed in Table 1 is still active.
Proceed to Test Step 4.
Result: None of the diagnostic codes listed in Table 1 are active.
Return the engine to service.
4. Replace the Suspect Injector
A. Replace the injector for the cylinder with the active diagnostic code. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove" and refer to Disassembly and Assembly, "Electronic Unit Injector - Install".
B. Use the electronic service tool to input the code for the new injector. Refer to Troubleshooting, "Injector Code - Calibrate".
C. Use the electronic service tool to check for active diagnostic codes.
Diagnostic Codes
Result: The diagnostic code is no longer active.
Return the engine to service.
Result: The diagnostic code is still active.
Proceed to Test Step 5.
5. Check if a Replacement ECM Eliminates the Fault
A. Contact the Dealer Solution Network (DSN).
B. If the Dealer Solution Network (DSN) recommends the use of a replacement ECM, install a replacement ECM. Refer to Troubleshooting, "ECM - Replace".
C. Use the electronic service tool to recheck the system for active diagnostic codes.
Diagnostic codes
Result: There are no active diagnostic codes with the replacement ECM.
Repair: Reconnect the suspect ECM. If the fault returns with the suspect ECM, replace the ECM.
Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.
Result: The diagnostic code is still present with the replacement ECM.
Contact the Dealer Solution Network (DSN).