855809 Mercury BOLT, (M6 x 100)

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.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Place identification marks on all tube assemblies for installation. Plug all lines and tube assemblies in order to prevent contamination.
Turn the fuel supply to the OFF position.
If necessary, loosen the dipstick tube (not shown).
Illustration 1 g01332971
Typical example
Illustration 2 g01332972
Typical example
Disconnect hose (4) from tube assembly (6) .
Disconnect fuel injection lines (1) from fuel injectors (3) .
Disconnect fuel injection lines (1) from fuel injection pump (5) .Note: Do not allow the unions to turn in the fuel injection pump when the fuel line nuts are loosened. Use two wrenches in order to disconnect the fuel injection lines from the fuel injection pump.
Remove fuel injection lines (1) .
Use suitable caps in order to plug the open ports of the fuel injection pump immediately.
Disconnect tube assembly (6) from fuel return line (2) .
Remove banjo bolt (9) and sealing washers (10) from fuel injection pump (5) .
Remove bolt (11) and remove tube assembly (6) .
Remove nuts (7) from fuel injectors (3). Remove fuel return line (2) and sealing washers (8) from fuel injectors (3) .
Use suitable caps in order to plug the open ports of the fuel injectors immediately.Installation Procedure
Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     276-1216     Injector Pipe Nut Tool     1    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 3 g01332971
Typical example
Illustration 4 g01332972
Typical example
Remove the caps from fuel injectors (3) and install new sealing washers (8) to the fuel injectors.Note: Washers (8) have two small holes. The position of the holes is not important.
Position fuel return line (2) onto fuel injectors (3) .
Install nuts (7) onto each fuel injector. Tighten the nuts to a torque of 23 N m (17 lb ft).
Position tube assembly (6) onto the engine. Loosely connect the tube assembly to fuel return line (2) .
Install banjo bolt (9) and new sealing washers (10) to fuel injection pump (5) .
Install bolt (11). Tighten the bolt to a torque of 11 N m (97 lb in).
Tighten banjo bolt (9) to a torque of 18 N m (13 lb ft). Tighten the nut to fuel return line (2) to a torque of 20 N m (15 lb ft).
Remove the caps from the fuel injection pump. Install fuel injection lines (1) to fuel injection pump (5) and to fuel injectors (3) .
Use Tooling (A) to tighten the nuts on fuel injection lines (1) to a torque of 30 N m (22 lb ft).Note: Do not allow the unions to turn in the fuel injection pump when the fuel line nuts are tightened.
Connect hose (4) to tube assembly (6) .
If necessary, tighten the dipstick tube (not shown) to a torque of 9 N m (80 lb in).
Turn the fuel supply to the ON position.
Prime the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for more information.