96783A 1 Mercruiser OIL COOLER

Table 1
Required Tools
Tool Part Number Part Description Qty
A 370-8376 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.
Turn the battery disconnect switch to the OFF position.
Turn the fuel supply to the OFF position.
Illustration 1 g02240074
Make temporary identification marks on plastic tube assemblies to show the correct position of the plastic tube assemblies.
Place a suitable container below the fuel filter base to catch any fuel that might be spilled.
Disconnect plastic tube assembly (2), plastic tube assembly (4), and plastic tube assembly (5) from the assembly of primary fuel filter (3).
Use Tooling (A) to plug the plastic tube assemblies. Use Tooling (A) to cap the ports in the primary fuel filter.
Disconnect the Original Equipment Manufacture (OEM) harness assembly from the connection on harness assembly (6) for water in fuel sensor (7).
Remove bolts (1) and remove the assembly of primary fuel filter (3) from the mounting bracket.
Illustration 2 g03463836
If necessary, follow Step 9a through Step 9e to disassembly the assembly of primary fuel filter (3).
Remove connection (8) and remove O-ring seal (9) (not shown). Use Tooling (A) to cap the connection . Use Tooling (A) to plug the ports in the primary fuel filter.
Remove connection (13) and remove O-ring seal (11) (not shown). Use Tooling (A) to cap the connection . Use Tooling (A) to plug the ports in the primary fuel filter.
Remove connection (12) and remove O-ring seal (10) (not shown). Use Tooling (A) to cap the connection . Use Tooling (A) to plug the ports in the primary fuel filter.
Remove water in fuel sensor (7) and remove O-ring seal (15) (not shown).
Remove the filter element from fuel filter canister (14). Refer to Operation and Maintenance Manual, "Fuel System Primary Filter (Water Separator) Element - Replace" for the correct procedure.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 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 the fuel filter base is clean and free from damage. If necessary, replace the complete fuel filter base and filter assembly.
Illustration 3 g03463836
If necessary, follow Step 2a through Step 2e to assembly primary fuel filter (3).
Remove plug from the fuel filter base and remove the cap from the connection. Install a new O-ring seal (9) (not shown) to connection (8). Install connection (8) to primary fuel filter (3). Tighten the connection to a torque of 20 N m (177 lb in).
Remove plug from the fuel filter base and remove the cap from the connection. Install a new O-ring seal (11) (not shown) to connection (13). Install connection (13) to primary fuel filter (3). Tighten the connection to a torque of 20 N m (177 lb in).
Remove plug from the fuel filter base and remove the cap from the connection. Install a new O-ring seal (10) (not shown) to connection (12). Install connection (12) to primary fuel filter (3). Tighten the connection to a torque of 20 N m (177 lb in).
Install a new O-ring seal (15) (not shown) to water in fuel sensor (7). Install water in fuel sensor (7). Tighten water in fuel sensor (7) hand tight.
Install a new filter element to fuel filter canister (14). Refer to Operation and Maintenance Manual, "Fuel System Primary Filter (Water Separator) Element - Replace" for the correct procedure.
Illustration 4 g02240074
Position the assembly of primary fuel filter (3) onto the mounting bracket.
Install bolts (1) to the assembly of primary fuel filter (3). 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 ports in the fuel filter base.
Ensure that the plastic tube assemblies are installed in the original positions. Failure to connect the plastic tube assemblies to the correct ports will allow contamination to enter the fuel system. Serious damage to the engine will result if contaminated fuel enters the fuel system.
Connect plastic tube assembly (2), plastic tube assembly (4), and plastic tube assembly (5) to primary fuel filter (3).
Connect the OEM harness assembly to the connection on harness assembly (6) for water in fuel sensor (7).
Turn the fuel supply to the ON position.
Turn the battery disconnect switch to the ON position.End By:
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.