Throttle Body Installation; Fuel Rail; Removal - Mercury MerCruiser Service Manual

Throttle Body Installation

1. Install any components that were removed during the inspection and cleaning process.
2. Install a new throttle body gasket into the groove in the bottom throttle body plate.
a
3. Align the dowels and install the throttle body onto the intake manifold.
4. If reusing the fasteners, apply Loctite 242 Threadlocker to the threads of the throttle body mounting screws.
Tube Ref No.
Loctite 242 Threadlocker
66
5. Install the two throttle body mounting screws. Tighten the screws to the specified torque. Install two throttle body nuts.
Description
Throttle body mounting screws and nuts
6. Install the flame arrestor and the engine cover. Tighten the clamp to the specified torque.
Description
Flame arrestor clamp

Fuel Rail

Removal

Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or
death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing engine or drive components.
Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot
start. Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated
and avoid prolonged exposure to vapors. Always check for leaks before attempting to start the engine, and wipe up any
spilled fuel immediately.
1. Disconnect the battery, removing the negative (–) battery lead first.
2. Remove the engine cover.
Using compressed air can cause serious injury. Always wear eye protection when working with compressed air to prevent
injury from ruptured hoses or flying debris.
3. Use compressed air to remove dirt and debris from the fuel rail and injector area before removing the rail and injectors.
4. Remove the PCM relay bracket as follows.
90-8M0099748 eng DECEMBER 2015
b
a - Gasket
b - Throttle body
56545
Description
!
!
!
Where Used
Threads of the throttle body mounting screws
WARNING
WARNING
CAUTION
© 2016 Mercury Marine
MPI ECT Fuel System
Part No.
92-809821
Nm lb‑in.
10 88.5
Nm lb‑in.
4 35.4
Page 5A-23
lb‑ft
–
lb‑ft
–