40023 21 Mercury WASHER, (12.80 mm x 24.0 mm x 2.4 mm) Stainless Steel

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
B     9U-6862     Tapered Brush     1    
9U-7237 Brush Extension     1    
C     9U-6863     Small Bore Brush     1    
9U-7237 Brush Extension     1    
D     8T-2998     Lubricant     1    
E     1U-5718     Vacuum Pump     1    
169-7372 Fluid Sampling Bottle     1    
4C-4057 Tube     1    
F     4C-6774     Vacuum Gun Kit     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 (E) to remove the fuel and oil from the cylinder head.Note: Tooling (F) is available to clean loose material from the sleeve bore and the cylinder.
Inspect the electronic unit injector sleeve for damage. If the electronic unit injector sleeve is worn or damaged use a new part for replacement.
Inspect the bore for the electronic unit injector and the electronic unit injector seat for carbon deposits.
Illustration 1 g01061148
Clean the carbon from the electronic unit injector sleeve, the sleeve bore for the electronic unit injector, and the end of the electronic unit injector, if the electronic unit injector is being reused. Clean the carbon from the electronic unit injector seat that is inside of the cylinder head. Use Tooling (B) in order to clean electronic unit injector seat (8) .
Use Tooling (C) in order to clean tip bore (9) .
Illustration 2 g01061150
Do not reuse O-ring seals. New O-ring seals must be used.
Install O-ring seals (10) on electronic unit injector (3) .
Lubricate the bore lightly with a 50/50 mix of clean engine oil and Tooling (D) .
Illustration 3 g01061151
Note: The injector code (11) will be used later if the injectors have been changed. Write down the injector code (11) which is located on the solenoid.
When a fuel injector group is serviced, the new fuel injector group's electronic injector code must be programmed into the engine's personality module software by using the calibration menu on the Electronic Service Tool. If the new fuel injector group's electronic code is not entered, the previous fuel injector group's characteristics are assumed.If it is not possible to immediately reprogram the electronic injector code of the injector into the personality module software, the engine will not be severely harmed. The new electronic injector code should be reprogrammed as quickly as possible in order to optimize engine performance.
Illustration 4 g01055070
Install electronic unit injector (3) .Note: Use new bolt (5) .
Install hold-down clamp (7) , spacer assembly (6) , and bolt (5) .
Tighten bolt (5) to a torque of 30 7 N m (22 5 lb ft).
Connect harness assembly (2) to electronic unit injector (3) . Tighten nuts to a torque of 2.5 0.25 N m (22 2 lb in).
Install bridge assemblies (4) onto the valve stems.
Illustration 5 g01019031
Install pressure plug (1) in the fuel manifold.End By: Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install".