864261 Mercruiser MANUAL, Service

Table 1
Required Tools
Tool Part Number Part Description Qty
A 388-1289 Capping Kit 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.
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.
Turn the fuel supply to the OFF position.
Illustration 1 g02988817
Typical example
Make a temporary identification mark on plastic tube assemblies (1) in order to show the correct position of the tube assemblies.
Place a suitable container below the fuel priming pump in order to catch any fuel that might be spilled. Drain primary filter (7). Refer to Operation and Maintenance Manual, "Fuel System Primary Filter (Water Separator) Element - Replace".
Disconnect plastic tube assemblies (1). Use Tooling (A) to plug the tube assemblies with new plugs.
Use Tooling (A) cap open connectors (2) on the fuel priming pump with new caps.
Remove primary filter (6) from fuel priming pump (4). Refer to Operation and Maintenance, "Fuel System Primary Filter (Water Separator) Element - Replace".
Remove bolts (7) from fuel priming pump (4). Remove fuel priming pump (4) from the mounting bracket.
If necessary, follow Steps 8.a through 8.d in order to disassemble fuel priming pump (4).
Remove connectors (2) from fuel priming pump (4). Use Tooling (A) to plug fuel priming pump (4).
Use Tooling (A) to cap connectors (2).
Remove plugs (5) from fuel priming pump (4). Use Tooling (A) to plug fuel priming pump (4).
Remove O-ring seals (3) from connectors (2) and plugs (5). Installation Procedure (Mechanical Priming Pump)
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.
Ensure that fuel priming pump (4) is clean and free from wear or damage. If necessary, replace the fuel priming pump.
Illustration 2 g02988817
Typical example
If necessary, follow Steps 2.a through 2.f in order to assemble fuel priming pump (4).
Install new O-ring seals (3) to plugs (5).
Remove caps from connectors (2). Install new O-ring seals (3) connectors (2).
Remove plugs from fuel priming pump (4).
Install connectors (2) to fuel priming pump (4).
Install plugs (5) to fuel priming pump (4).
Tighten the plugs and the connectors to a torque of 20 N m (14 lb ft).
Position fuel priming pump (4) on the mounting bracket. Install bolts (7) to the fuel priming pump . Tighten the bolts to a torque of 44 N m (32 lb ft).
Remove the plugs from the plastic tube assemblies. Remove the caps from the connectors.
Connect plastic tube assemblies (1) to connectors (2). Note: Ensure that the plastic tube assemblies are installed in the original positions.
Install a new primary filter (6) to fuel priming pump (4). Refer to Operation and Maintenance Manual, "Fuel System Primary Filter (Water Separator) Element - Replace".
Turn the fuel supply to the ON position.
Prime the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime".