804522 Mercury CLAMP (INJECTOR) DESIGN II

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     422-7170     Capping Kit     1    
B     367-2771     Injector Pipe Nut Tool     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.
Turn the fuel supply to the OFF position.
Illustration 1 g02720484
Disconnect hose assembly (2) from the fuel injector. Remove plastic tube assembly (3) from clip (1) .
Use Tooling (A) to cap the fuel injector. Use Tooling (A) to plug hose assembly (2) .
Disconnect hose assembly (6) from the connection on plastic tube assembly (3) .
Use Tooling (A) to cap the connection on plastic tube assembly (3) . Use Tooling (A) to plug hose assembly (6) .
Remove banjo bolt (5) and remove sealing washers (4) (not shown).
Use Tooling (A) plug plastic tube assembly (3) . Use Tooling (A) plug fuel filter base (12) .
Remove clip (10) from plastic tube assembly (3) and plastic tube assembly (11) .
Remove plastic tube assembly (3) and plastic tube assembly (11) from clip (8) and clips (9) .
Disconnect plastic tube assembly (11) from fuel filter base (12) .
Use Tooling (A) plug fuel filter base (12) . Use Tooling (A) cap plastic tube assembly (11) .
Disconnect plastic tube assembly (3) and plastic tube assembly (11) from fuel injection pump (7) .
Use Tooling (A) to cap the connections on fuel injection pump (7) .
Use Tooling (A) to plug plastic tube assembly (3) and plastic tube assembly (11) .
Illustration 2 g02692736
Disconnect fuel injection lines (13) from fuel injectors (14) .
Use Tooling (B) in order to disconnect fuel injection lines (13) from fuel injection pump (7) .
Remove fuel injection line (13) as an assembly.
Use Tooling (A) in order to cap ports of fuel injectors (14) .
Use Tooling (A) in order to cap ports of fuel injection pump (7) .
Illustration 3 g02692776
If necessary, follow Step 20.a through Step 20.c in order to disassemble the fuel injection line assembly.
Make temporary identification marks on all the clamps to show position and orientation prior to removal. Remove clamp (15) , clamp (16) and clamp (17) from fuel injection lines (13) .
Make temporary identification marks on all the clamps to show position and orientation prior to removal. Remove clamp (18) , clamp (19) and clamp (20) from fuel injection lines (13) .
Remove fuel injection lines (13) .Note: Make temporary identification marks on all the fuel injection lines prior to removal.