866463A02 Mercruiser COVER ASSEMBLY, Back

Fluid Spillage ContainmentCare must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "Tools And Shop Products Guide", NENG2500 for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.
When disassembling the engine for inspection or repair, the fuel lines should be removed as a unit and reinstalled as a unit. If any fuel lines are replaced, the fuel line clamps must be reinstalled in the exact locations as previously installed from the factory. The fuel line clamps are strategically placed to support the lines and prevent them from vibrating. Continual vibration could cause the fuel lines to crack.
Before removing any clamps, mark their location with tape, paint, marker or some other non-damaging method. This will help insure that the clamps are reinstalled in the correct location. Use a 4C-9738 Torque Screwdriver or similar tool to tighten the clamp screws to a torque of 2.25 N m (20 lb in). The proper torque is important so the fuel lines are held securely and in the proper alignment. Over torquing applies unnecessary pressure and can spread the lines apart.
Do not force fuel injection line ends into position and then begin to tighten the nuts on the ends of the lines. The result will be added strain on the lines. If needed, gently bend the lines by hand until the lines are the correct shape for the nuts to be easily started. 1. Remove turbocharger and exhaust manifold guards (1).2. Clean the area around each fuel injection line connection. 3. Remove bolt and washer (2) from fuel injection line support (3).
Do not let the tops of the fuel nozzles turn when the fuel injection lines are loosened. If the tops of the nozzles turn, the nozzles will be damaged.
4. Disconnect two fuel injection lines (4) at the fuel nozzles and at the fuel injection pump housing. Remove two fuel injection lines (4). Put 5F-3807 Caps and 2F-2990 Plugs on the fuel injection lines, pumps, and nozzles to keep dirt and foreign material out of the fuel system. 5. Remove bolt and washer (5) from two fuel injection line supports (6). One support is not shown.
Do not let the tops of the fuel nozzles turn when the fuel injection lines are loosened. If the tops of the nozzles turn, the nozzles will be damaged.
6. Disconnect four fuel injection lines (7) at the fuel nozzles and at the fuel injection pump housing. Remove four fuel injection lines (7). Put 5F-3807 Caps and 2F-2990 Plugs on the fuel injection lines, pumps, and nozzles to keep dirt and foreign material out of the fuel system. The following step are for installation of the fuel injection lines. 7. Remove the protection covers from the fuel line connections. Put the fuel injection lines (7) in position and tighten the nuts at the fuel nozzles and at the fuel injection pump housing until they are finger tight.8. Install bolt and washer (5) onto two fuel injection line supports (6). One support is not shown.9. Use Tool (A) and tighten the nuts to a torque of 40 7 N m (30 5 lb ft).
Do not let the tops of the fuel nozzles turn when the fuel lines are tightened. If the tops of the nozzles turn, the nozzles will be damaged.
Do let the tops of the fuel nozzles turn when the fuel injection lines are tightened. If the tops of the nozzles turn, the nozzles will be damaged.
10. Put fuel injection lines (4) in position and tighten the nuts at the fuel nozzles and at the fuel injection pump housing until they are finger tight.11. Install bolt and washer (2) onto fuel injection line support (3).12. Use Tool (A), a wrench, and a torque wrench to tighten the nuts. Tighten the nuts to a torque of 40 7 N m (30 5 lb ft). 13. Install turbocharger and exhaust manifold guards (1).14. Remove (bleed) the air from the fuel lines. See the topic, "Priming The Fuel System" in the Operation & Maintenance Manual.