803002 Mercruiser BRUSH/HOLDER ASSEMBLY

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     4C-5597     Anti-Seize Compound     -    
B     195-4609     Seal Pick     1    
C     -     Isopropyl Alcohol     -    
D     5P-4996     Plug     2    
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.
Illustration 1 g02300314
Remove sheet assembly (1) .
Illustration 2 g02300333
Illustration 3 g02300500
Remove tube assemblies (2) and tube assembly (7). Plug the coolant lines with Tooling (D) .
Disconnect cable assembly (4) and remove spark plug (3) .
Remove flame detection sensor (8) and disconnect heated nozzle (9) .
Remove nuts (5), combustion head (6), gasket (13), tube assembly (12), and gasket (11) .Note: Gaskets are one time use. Install new gaskets upon installation.
If required, remove studs (10) .
Illustration 4 g02482996
Use Tooling (B) in order to remove O-ring seals (14) and (15) from the heated nozzle (9). Discard the O-ring seals.Installation Procedure
Install combustion head (6) in the reverse order of removal.
Apply Tooling (A) onto the threads of studs (10). Tighten studs (10) to a torque of 17 2 N m (150 18 lb in).
Apply Tooling (A) onto the threads of the studs and nuts (5). Tighten nuts (5) in a crisscross pattern to a torque of 23 3 N m (204 27 lb in). Tighten nuts (5) again in a crisscross pattern to a torque of 28 3 N m (21 2 lb ft). Tighten nuts (5) again in a crisscross pattern to a torque of 28 3 N m (21 2 lb ft).
Use caution when you are using isopropyl alcohol. Avoid prolonged skin contact with isopropyl alcohol.Vapors may be harmful if inhaled. Use only in a well ventilated area. Do not smoke while using isopropyl alcohol.Isopropyl alcohol is flammable. Do not use near an open flame or near welding operations. Keep isopropyl alcohol away from heated surfaces exceeding 482°C (900°F).
Note: This connection is an electrical connection and cannot be lubricated with a petroleum-based lubricant. Isopropyl alcohol is the only approved lubrication for this connection.
Lubricate new O-ring seals (14) and (15) with Tooling (C) prior to installation.
Apply Tooling (A) to the threads of flame detection temperature sensor (8) and install the sensor. Tighten flame detection temperature sensor (8) to a torque of 45 5 N m (33 3 lb ft).
Tighten spark plug (3) to a torque of 47 4 N m (35 3 lb ft).
Check the coolant level. If necessary, refer to Operation and Maintenance Manual, "Coolant - Change" for the proper filling procedures.
Perform the ARD ignition test. Refer to Troubleshooting Manual, "ARD Ignition - Test".