804535 Mercury COVER (TRACKER VALVE)

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     422-7170     Capping Kit     1    Start By:
Remove the secondary fuel filter and the fuel filter base and bracket. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install" for the correct procedure.
Remove the water separator and fuel filter (Primary) and bracket. Refer to Disassembly and Assembly, "Water Separator and Fuel Filter (Primary) - Remove and Install" for the correct procedure.
Remove the rocker shaft and pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrods - Remove" for the correct procedure.
Remove the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install" for the correct procedure.
Remove the crankcase breather canister and plastic tube assemblies. Refer to Disassembly and Assembly, "Crankcase Breather - Remove" for the correct procedure.
Remove the fuel injectors. Refer to Disassembly and Assembly, "Fuel Injector - Remove" for the correct procedure.
Remove the glow plugs. Refer to Disassembly and Assembly, "Glow Plugs - Remove and Install" for the correct procedure.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
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.
Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct draining procedure.
Illustration 1 g02717216
Disconnect the upper radiator hose from water temperature regulator housing (1) on the cylinder head.
Illustration 2 g02717217
Illustration 3 g02717219
Loosen hose the clamp and disconnect the tube assembly and hose assembly from connection (11) .
Remove bolt (3) and remove bracket (2) from the cylinder head.
Remove bolts (4) and bolts (9) from bracket (5) and bracket (10) .
Disconnect plastic tube assembly (6) and plastic tube assembly (8) from fuel injection pump (7) .
Use Tooling (A) to plug plastic tube assembly (6) and plastic tube assembly (8) .
Use Tooling (A) to cap connections on fuel injection pump (7) .
If necessary, remove the tube assembly from the cylinder head and the boost control on the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump- Remove (With Boost Control)" for the correct procedure.
Remove bolts (12) from the clips for tube assembly (13) .
Illustration 4 g02717238
Remove bolts (14) from bypass tube (15) .
Remove bypass tube (15) from the cylinder head.
Remove O-ring seal (16) and O-ring seal (17) from bypass tube (15) .
Illustration 5 g02717247
Illustration 6 g02717248
Sequence for tightening the bolts for the cylinder head
Gradually loosen bolts (18) in the reverse numerical order to the tightening sequence. Refer to the Illustration 6.Note: Follow the correct sequence in order to help prevent distortion of the cylinder head.
Remove bolts (18) from cylinder head (19) .
Attach a suitable lifting device to cylinder head (19) . Support the weight of the cylinder head. The weight of the cylinder head is approximately 96 kg (212 lb).Note: A spreader bar must be used in order to distribute the weight of the cylinder head during the lifting operation.
Use the suitable lifting device to lift cylinder head (19) off the cylinder block.Note: Do not use a lever to separate the cylinder head from the cylinder block. Take care not to damage the machined surfaces of the cylinder head during the removal procedure.
Place the cylinder head on a surface that will not scratch the face of the cylinder head.
Illustration 7 g02717250