Fuel Injection Pump Removal - Mercury MerCruiser D2.8L D-Tronic Service Manual

SERVICE MANUAL NUMBER 22

Fuel Injection Pump Removal

Safety glasses should be worn while working on fuel injection system. The fuel
injection pump will generate pressures in excess of 27000 kPa (3900 psi). Use
caution when removing injectors, injector lines or bleeding air from injection
system.
1. Remove the hex-head plug in cylinder number 1 glow plug hole, or remove cylinder
number 1 cylinder glow plug, if equipped.
Typical
2. Attach Remote Starter Switch 91-52024A1, or similar, to the starter solenoid in
accordance with manufacturer's instructions.
Avoid breathing difficulties or injury. Diesel fuel and diesel fuel vapors may be
expelled from cylinder openings causing breathing difficulty or injury. Do NOT
crank the engine using the ignition key switch when establishing Top Dead Center
(TDC) of a cylinder because the engine could start unexpectedly. Use a suitable
remote starter switch. As an added safety measure remove the key from the ignition
switch to prevent start up.
3. Position a piece of thin paper, or similar, near the glow plug hole opening of the cylinder
number 1.
NOTE: When cylinder number 1 begins compression stroke, combustion air will be expelled
from the cylinder through the glow plug hole opening. Watch for movement of the paper.
Stop cranking on compression stroke.
4. Using the remote starter switch, crank the engine to locate compression stroke. Stop
cranking on cylinder number 1 compression stroke.
5. Slowly rotate the engine to Top Dead Center (TDC) using a suitable hand tool.
NOTE: Attach and use Crankshaft Tool 91-814827, if necessary.
90-860074--1 FEBRUARY 2002
a - Hex Head Plug (or Glow Plug, If Equipped)
b - Port Side Of Cylinder Head
WARNING
a
b
CAUTION
INJECTION PUMP
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