5442400TP Mercruiser STERNDRIVE, Bravo-III X (1.81:1 Ratio)

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.
Contact with high pressure fuel may cause personal injury or death. Wait 60 seconds after the engine has stopped to allow fuel pressure to purge before any service or repair is performed on the engine fuel lines.
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.Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Fuel injection lines MUST only be used once. Discard all fuel injection lines after use.
Clean the common rail area prior to the removal of fuel lines.
Note: Cleanliness is an important factor. Before the removal procedure, the exterior of the engine should be thoroughly cleaned. The majority of the cleaning should be directed toward the fuel lines. This will help to prevent dirt from entering the internal mechanism.Before replacing any high pressure fuel line, follow the instructions that are listed below. Replace the high pressure fuel line with the correct Fuel Injection Lines Gp.Note: Do not reuse the old clamp assembly and the old fuel line.Note: Failure to follow this procedure may result in a leaking fuel line.Note: The following procedures were written for the complete removal of all of the fuel lines and clamps. If only specific fuel lines need to be replaced then only remove the fuel lines and clamps that need replacement.
Turn the fuel supply to the OFF position.
Disconnect the battery. Refer to Operation and Maintenance Manual, "Battery or Battery Cable - Disconnect".
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Remove bolts (9) and clamps (8) at Locations (1), (2), (3), and (4). Take note of rubber grommets (7) in clamps (8) at Locations (1), (2), (3), and (4).
Loosen nut (6) on each end of fuel injection line (5). Remove fuel injection line (5). Repeat for the remaining fuel injection lines. Discard the fuel injection lines. Installation Procedure
Fuel injection lines MUST only be used once. Discard all fuel injection lines after use.
Note: Cleanliness is an important factor. Ensure that no debris gets introduced into the fuel system during the installation procedure. If any parts are worn or damaged, use new parts for replacement.
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Install a new fuel injection line (5). Hand tighten nut (6) on each end of the fuel injection line. Repeat for the remaining fuel injection lines.
Install clamps (8) at Locations (1), (2), (3), and (4). Make sure that rubber grommets (7) are placed correctly in clamps (8) at Locations (1), (2), (3), and (4). Failure to correctly place the grommet in the clamp could result in a failed fuel line. Install bolts (9) for clamps (8) hand tight. Note: Ensure that the fuel injection lines are centered in the nuts prior to tightening. Do not use excessive force or bending in order to assemble the fuel injection lines.
Tighten nuts (6) at the fuel rail for the fuel injection lines to a torque of 27 3 N m (239 27 lb in).
Tighten nuts (6) at the quill tube to a torque of 15 3 N m (135 27 lb in). Turn nuts (6) at the quill tube for an additional 60 5 degrees.
Tighten the bolts for clamps (1), (2), (3), and (4) to a torque of 12 3 N m (105 27 lb in).
Connect the battery. Refer to Operation and Maintenance Manual, "Battery or Battery Cable - Disconnect".
Turn the fuel supply to the ON position.