803664 Mercury BOLT

Table 1
Required Tools
Tool Part Number Part Description Qty
A 278-4138 Capping Kit 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 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.
Note: Put identification marks on all hoses on all hose assemblies and on wires and all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. Plugging and capping hose assemblies and tube assemblies will help to prevent fluid loss and helps to keep contaminants from entering the system.
Turn the fuel supply to the OFF position.
Turn the battery disconnect switch to the OFF position.
Illustration 1 g02481081
Illustration 2 g02625722
Remove bolt (2) from tube clamp (7). Remove clamp plate (8) and isolator (9) from fuel injection line (1) and fuel injection line (4).
Clean the area around the nuts for the fuel injection line (1) and fuel injection line (4). Ensure that the area is free from contamination before beginning disassembly.
Disconnect fuel injection line (1) and fuel injection line (4) from the electronic unit injector.
Disconnect fuel injection line (1) and fuel injection line (4) from fuel manifold (5).
Use Tooling (A) in order to plug the open port in the electronic unit injector immediately.
Remove fuel injection line (1) and fuel injection line (4). Discard the fuel injection lines.
Remove bracket (10) and isolator (11).
Use Tooling (A) in order to plug the open port in fuel manifold (5) immediately.
Remove seal (3) from the electronic unit injector and cylinder head (6).
Use Tooling (A) in order to plug the open port for the electronic unit injector.
Repeat Step 5 through Step 12 in order to remove the remaining fuel injection lines from the fuel manifold to the electronic unit injectors.
Illustration 3 g02625818
Slide locking tab (13) into the unlocked position. Disconnect harness assembly (14) from coolant temperature sensor (12).
Disconnect harness assembly (17) from fuel pressure sensor.
Cut cable strap (15).
Remove bolt (16) and bolt (19) (not shown) from bracket (18).
Position bracket (18) and the harness assembly away from the fuel injection pump.
Illustration 4 g02481080
Remove bolt (20) from the tube clip.
Remove bolt (21) and spacer (22) (not shown) from the tube clip.
Disconnect fuel injection line (24) at fuel injection pump (23).
Disconnect fuel injection line (24) at fuel manifold (5).
Remove fuel injection line (24). Discard the fuel injection lines.
Use Tooling (A) in order to plug all open ports immediately in fuel manifold (5) and in fuel injection pump (23).