863458 Mercruiser HOSE, Thermosat Housing To Port Manifold

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     276-1216     Injector Pipe Nut Tool     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 Systems Operation, Testing and Adjusting Manual, "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 1 g03483056
Remove bolts (1) and walkway assembly (2) .
Illustration 2 g03483058
Remove bolts (3) in order to remove plate (4) .
Remove the fuel injection lines. Refer to Disassembly and Assembly Manual, "Fuel Injection Lines - Remove".
Illustration 3 g03383303
The fuel manifold is shown with fuel injection lines in position.
If necessary, remove fuel pressure sensor (7). Refer to Disassembly and Assembly, "Fuel Pressure Sensor - Remove and Install".
If fuel pressure sensor (7) does not require removal, disconnect the plug on harness assembly (11) from fuel pressure sensor (7) .
Disconnect tube assembly (9) from fuel pressure relief valve (8). The tube assembly can be secured with a nut or with a banjo bolt. Immediately cap the open port in the pressure relief valve with a new cap. Immediately plug the open end of the tube assembly with a new plug.
If necessary, remove fuel pressure relief valve (8). Use a deep socket in order to remove the fuel pressure relief valve.Note: The fuel pressure relief valve should only be removed at Position (X). The fuel pressure relief valve is a two-piece assembly which should not be disassembled.
Remove bolts (6) from fuel manifold (5). Note the position of any brackets that are secured by the bolts.
Remove fuel manifold (5) from mounting bracket (10) .
If necessary, remove the bolts and remove mounting bracket (10) .Installation Procedure
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 Systems Operation, Testing and Adjusting Manual, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Ensure that all ports on the fuel manifold are capped. Ensure that the fuel manifold is externally clean and free from damage.Note: Do not install a fuel manifold that has not been capped. All caps must be left in place until the fuel injection lines or the fuel pressure sensor are installed.
Illustration 4 g03383303
If necessary, install mounting bracket (10) and install the bolts. Tighten the bolts to a torque of 22 N m (195 lb in).
Position fuel manifold (5) onto mounting bracket (10). Install bolts (6) to the fuel manifold finger tight. Ensure that any brackets that are secured by bolts (6) are installed in the correct position.
Loosely install a new set of fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for more information.
Tighten bolts (6) to a torque of 22 N m (195 lb in).
Use Tooling (A) to tighten the nuts on the fuel injection lines to a torque of 30 N m (22 lb ft). Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for more information.
If necessary, install a new fuel pressure relief valve (8). Use a deep socket in order to tighten the fuel pressure relief valve. Tighten the fuel pressure relief valve to a torque of 120 N m (89 lb ft).Note: Fuel pressure relief valve (8) must only be tightened at Position (X). The fuel pressure relief valve is a two-piece assembly which should not be disassembled.
Remove the plug from tube assembly (9). Remove the cap from the appropriate port in fuel manifold (5). Connect tube assembly (9) to fuel pressure relief valve (8). If tube assembly (9) is secured with a nut, tighten the nut to a torque of 26 N m (230 lb in).
If tube assembly (9) is secured with a banjo bolt, install the new sealing washers and the banjo bolt (9). Tighten the banjo bolt to a torque of 21 N m (186 lb in).
If fuel pressure sensor (8) was removed from fuel manifold (5), install a new sealing washer and fuel pressure sensor (8). Refer to Disassembly and Assembly, "Fuel Pressure Sensor - Remove and Install" for more information.If fuel pressure sensor (8) was not removed from fuel manifold (5), connect the plug on harness assembly (11) to fuel pressure sensor (8) .
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for more information.