MAY 2003 31. Attach the new main wire harness in the reverse procedure of removal. 32. Reassemble the engine. Using the shop manual, take special care when reassembling the following: Verify that the fuel pressure regulator return hose is not pinched between the intake manifold and the starboard valve cover when installing the intake manifold. You can reuse the stamped metal intake manifold gasket when installing the intake manifold. Make sure the intake manifold upper cover gasket (black rubber O-ring type seal) is in its groove before installing the upper cover.
You must follow the tightening procedure (page 9 and page 10 of this bulletin) for the intake components to prevent vacuum leaks or damage to the intake manifold and cover. TORQUE: INTAKE MANIFOLD 8 mm flange bolt: 27 N•m (2.7 kg-m, 20 ft-lb) 8 mm flange nut: 27 N•m (2.7 kg-m, 20 ft-lb) 6 mm flange bolt: 12 N•m (1.2 kg-m, 9 ft-lb) INTAKE COVER 6 mm flange bolt: 10 N•m (1.0 kg-m, 7 ft-lb) THROTTLE BODY 8 mm flange bolt: 22 N•m (16 ft-lb) Do not over-tighten the 6 mm engine under cover special bolts. Apply a small amount of marine grease on these bolt threads to preserve the threads in the castings.
Do not forget to connect the coolant indicator hose when installing the starboard engine under cover. Verify that the trim switch wire harness is routed correctly. Verify that the throttle cables are routed correctly and not twisted when installing the throttle body. 33. Proceed to the following page for Throttle Cable Replacement . Page 15 of 2 0