893694T02 Mercury COVER ASSEMBLY

Table 1
Required Tools
Tool Part Number Part Description Qty
A 339-9354 Fuel LineCap Kit 1
265-2256 Wipers 1 Start By:
Remove the air inlet manifold.
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.Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.Dispose of all fluids according to local regulations and mandates.
Do not open the high pressure fuel system without allowing the fuel system to purge. After the engine has shut down, allow the fuel system to purge for ten minutes. This operating fuel system contains high pressure. Exposure to high pressure fuel can result in personal injury.
Note: Use Tooling (A) to cap tube assemblies, fittings, ports, and any opening in the fuel system in order to prevent contamination.Note: Do not remove all the quills in order to maintain the alignment of the rail. Maintain at least two quills attached to the rail at all times. If necessary, replace with new quill.
Illustration 1 g01285837
Remove bolt (1) and the clamp from tube assembly (2).
Illustration 2 g01822393
Illustration 3 g01443406Note: Cap tube assemblies, fittings, ports, and any opening in the fuel system in order to prevent contamination.
Disconnect tube assembly (3) and remove the bolts on tube assembly (2). Remove bolts (5). Disconnect tube assembly (4). Remove tube assembly (2) and the O-ring seals. Remove bolts (6). Note: If necessary, secondary fuel filter lines may need removed in order to remove tube assembly (2).Note: Replace with new bolts (5)
Illustration 4 g01285008
Illustration 5 g01822394
Remove bolts (9). Remove bolts (10) and bolts (11). Repeat for the opposite side. Note: Replace with new bolts (9)
Remove tube assembly (7). Remove tube assembly (8) and the O-ring seal.
Illustration 6 g01822395
Attach a suitable lifting device onto fuel rail (13). The weight of fuel rail (13) is approximately 60 kg (131 lb). Remove bolts (12). Remove fuel rail (13).
Place the high-pressure fuel rail on a clean surface. Support the rail so the weight is not resting on the quills. All openings should be capped or plugged in order to prevent contamination.
Repeat Step 5 for the opposite side. Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A 339-9354 Fuel LineCap Kit 1
265-2256 Wipers 1 Note: When Tooling (A) is removed be careful to prevent contamination.
Install the high-pressure fuel rail (13) in the reverse order of removal.
Illustration 7 g01443632
Tighten bolts (12) in the sequence that is shown in Illustration 7. Tighten bolts (12) to a torque of 100 20 N m (74 15 lb ft).
Install bolts (10) and (11) hand tight. Evenly tighten new bolts (9) to a torque of 20 N m (15 lb ft). Note: New bolts (9) do not rotate more than 90 degrees at a time.
Evenly tighten new bolts (9) to a torque of 40 N m (30 lb ft). Note: New bolts (9) do not rotate more than 45 degrees at a time.
Tighten bolts (10) and (11) to a torque of 40 10 N m (30 7 lb ft).
Position bolts (6) and tighten b