44574 Mercruiser CAP

Table 1
Required Tools
Tool Part Number Part Description Qty
A 370-8376 Capping Kit 1
B - P80 Emulsion 1
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High-Pressure Fuel Lines" for safety information.Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Note: Put identification marks on all hoses on all hose assemblies and all tube assemblies for installation purposes. Plug or cap all hose assemblies and tube assemblies. Plugging and capping all hose assemblies and tube assemblies will help to prevent fluid loss and helps to keep contaminants from entering the system.
Turn the fuel supply to the OFF position.
Turn the battery disconnect switch to the OFF position.
Thoroughly clean the area around all low-pressure fuel pipes before disassembly.
Illustration 1 g06383824
Remove bolt (1) from clamp (13) (not shown).
Remove clamp (13) (not shown).
Make temporary identification marks on clamp (4) and clamp (13) for installation purposes.
Use suitable tooling to expand clamp (4). Move clamp (4) away from exhaust cooler elbow (5).
Use suitable tooling to expand clamp (13). Move clamp (13) away from stub pipe (12).
Remove hose (3), exhaust cooler elbow (5) and from stub pipe (12).
Remove bolt (10) from stub pipe (12) and remove stub pipe (12) from the cylinder head.
Remove bolt (11) from clips (11B).
Disconnect tube assembly (7) from connection (6) and tube assembly (9) from connection (8) and move away from the engine.
Illustration 2 g06384317
Remove leak off pipe clips (19).
Remove banjo (14), sealing washer (15) (not shown), and sealing washer (17) (not shown) from banjo connection (18).
Illustration 3 g06383847
Remove bolts (25) from fuel pressure regulator (23).
Disconnect tube connection (22) from fuel pump (24).
Disconnect tube connection (26) from fuel pump (24).
Remove clip (27) from hose (28).
Disconnect hose assembly (28) from injectors (20).Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A T412504 Capping Kit 1
B - P80 Emulsion 1
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High-Pressure Fuel Lines" for safety information.Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Illustration 4 g06383890
Install new o-ring seals (29) to leak off pipe assembly (28).
Illustration 5 g06384317
Use Tooling (B) to lubricate leak off connections (21). Install the connections to electronic unit in