803897Q 1 Mercruiser FILTER KIT, Fuel

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     6V-6640     Sealant     1    
B     -     Guide Studs
M8 by 80 mm     2    
C     319-6486     Alignment Tool     1    
- Bolts
M10 by 50 mm     3    
D     1U-6396     O-Ring Assembly Compound     1    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the wiring harness assembly is correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness and the convoluting.
Ensure that the front housing is clean and free from damage. If necessary, replace the front housing.If necessary, install blanking plugs to a new front housing. Use Tooling (A) in order to seal all D-plugs.
Clean all the gasket surfaces of the cylinder block.
Illustration 1 g02490296
Illustration 2 g02490297
Inspect dowel (16) and dowel (17) for damage. If necessary, replace the dowels in cylinder block (15) .
Install thrust washer (14) into the recess in cylinder block (15) . Refer to Disassembly and Assembly, "Camshaft - Install" for more information.
Install Tooling (B) to cylinder block (15) . Refer to Illustration 2.
Align a new gasket (13) with Tooling (B) . Install the gasket to cylinder block (15) .Note: Ensure that two circular Tabs (X) on the gasket are engaged in two Holes (Y) in cylinder block (15) . Ensure that dowel (17) in cylinder block (15) is engaged on the gasket.
Install Tooling (C) to cylinder block (15) .
Install the front housing over Tooling (B) and Tooling (C) onto cylinder block (15) .
Illustration 3 g02490298
(10) M8 by 20 mm (11) M8 by 35 mm (12) M8 by 25 mm
Illustration 4 g01998054
Install bolts (12) to front housing (7) finger tight.
Remove Tooling (B) .
Loosely install bolts (10) and bolts (11) . Refer to Illustration 3 for the correct position of the bolts.
Tighten bolts (10) , bolts (11) and bolts (12) in the sequence that is shown in Illustration 4 to a torque of 28 N m (248 lb in).
Remove Tooling (C) from the cylinder block.
Illustration 5 g02488340
Install a new O-ring seal (8) and a new O-ring seal (9) to bypass tube (5) . Use Tooling (D) in order to lubricate the O-ring seals.
Install bypass tube (5) to the cylinder head. Install bolts (6) . Tighten the bolts to a torque of 9 N m (80 lb in).
Connect harness assembly (2) to coolant temperature sensor (3) .
Slide locking tab (1) (not shown) into the locked position.
Position harness assembly (2) onto bypass tube (5) . Install a new cable strap (4) .Note: Ensure that the cable strap meets Original Equipment Manufactures (OEM) specification.End By:
Install the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install" for the correct procedure.
Install the timing gears. Refer to Disassembly and Assembly, "Gear Group (Front) - Install" for the correct procedure.
If the engine has an accessory drive, install the accessory drive. Refer to Disassembly and Assembly, "Accessory Drive - Remove and Install" for the correct procedure.
Install the engine oil pan plate . Refer to Disassembly and Assembly, "Engine Oil Pan Plate - Remove" for the correct procedure.
Install the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley - Install" for the correct procedure.
Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install" for the correct procedure.
Install the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install" for the correct procedure.
Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Fill" for the correct procedure.