863439 Mercruiser STUD

Table 1
Required Tools
Tool Part Number Part Description Qty
A 388-1289 Capping Kit 1 Start By:
Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove" for the correct procedure.
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 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.
Note: Plug or cap all open ports with new plugs or new caps.
Thoroughly clean the area around fuel manifold (12).
Illustration 1 g03784524
Illustration 2 g03784525
Disconnect the wiring harness from fuel pressure sensor (3).
Disconnect hose assembly connection (9) from fuel injection pump (8).
Disconnect hose assembly connection (6) from fuel distribution block (5).
Remove bolts (1) from fuel manifold (2). Remove the fuel manifold from the valve mechanism cover (4).
If necessary, follow Step 6.a through Step 6.e in order to remove plastic tube assembly (7).
Release hose clamp (10) on plastic tube assembly (7).
Disconnect plastic tube assembly (7) from the fuel manifold (2).
Use Tooling (A) to cap the open port in fuel manifold (2) with a new cap.
Remove seal (11).
Use Tooling (A) to plug the open end of plastic tube assembly (7) with a new plug.
If necessary, remove fuel pressure relief valve (12) and O-ring seal (13) (not shown) from the fuel manifold.
If necessary, remove fuel pressure sensor (3) from the fuel manifold. 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 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 plugged. All plugs and caps must be left in place until the fuel injection lines are about to be installed.
Illustration 3 g03784524
Illustration 4 g03784525
If necessary, install fuel pressure relief valve (12) and new O-ring seal (13) (not shown) to fuel manifold (2). Tighten fuel pressure relief valve (12) to a torque of 100 N m (74 lb ft).
If necessary, install fuel pressure sensor (3) to the fuel manifold. Tighten fuel pressure sensor (3) to a torque of 70 N m (52 lb ft).
If necessary, follow Step 4.a through Step 4.d in order to install tube assembly (7) to fuel manifold (2).
Position hose clamp (10) onto plastic tube assembly (7).
Install new seal (11) into plastic tube assembly (7).
Install plastic tube assembly (7) to fuel manifold (2). Note: Ensure that the plastic tube assembly is correctly orientated.
Tighten hose clamp (10) securely.
Position fuel manifold (2) onto valve mechanism cover (4). Install bolts (1) to fuel manifold (2) finger tight.
Install new fuel injection lines finger tight. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the installation procedure. Note: Do not torque the nuts for the fuel injection lines at this stage of the assembly procedure.
Tighten bolts (1) to a torque of 25 N m (221 lb in).
Tighten the nuts for the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct torque.
Remove the plug from connection (9) and install plastic tube assembly (7) to the fuel injection pump (8).
Remove the plug from connection (6) and install plastic tube assembly (7) to distribution block (5).
For the remaining installation procedure for the fuel injection lines, refer to Disassembly and Assembly, "Fuel Injection Lines - Install". End By:
If a new fuel manifold is installed, it will be necessary to use the electronic service tool in order to perform the"Rail Pressure Valve Learn Reset" procedure.