804519 Mercury FITTING (AIR/FUEL) PORT

Table 1
Required Tools
Tool Part Number Part Description Qty
A 367-2771 Injector Pipe Nut Tool 1
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.
Ensure that all the fuel injection lines are clean and free from damage. Replace any fuel injection lines that are worn or damaged.
Illustration 1 g02692736
Illustration 2 g02692776
Illustration 3 g02720972
Typical Example
If necessary, follow Step 2.a through Step 2.d in order to assemble the fuel injection lines.
Assemble fuel injection lines (13) into the correct order.
Install isolator (23) for clamp (16) to fuel injection lines (13). Note: Ensure that the isolator is correctly position and oriented onto fuel injection lines.
Position top section (22) onto isolator (23) and install bottom section (24) to top section (22). Loosely install bolt (21) hand tight.
Repeat Step 2.a through Step 2.c in order to install the remaining clamp (15) , clamp (17), clamp (18), clamp (19) and clamp (20).
Remove the caps from the ports of fuel injectors (14). Remove the caps from the ports of fuel injection pump (7).
Remove the caps from fuel injection lines (13)
Loosely position the assembly of fuel injection lines (13) onto fuel injection pump (7) and fuel injectors (14). Tighten the nut for fuel injection line (13) hand tight. Note: Ensure that the fuel injection lines are correctly seated into the connections for the fuel injection pump and the fuel injectors.
Use Tooling (B) to tighten the nuts on fuel injection line (13) to a torque of 34 N m (301 lb in). Note: Ensure that the fuel injection lines do not contact any other engine component.
Illustration 4 g02720997
Use a suitable tool in order to hold the clamps in Position (A). Tighten bolts (20) for the clamps to a torque of 9 N m (80 lb in).
Illustration 5 g02720484
Remove the plug from fuel filter base (12). Remove the cap from plastic tube assembly (11). Remove the cap from the connections on fuel injection pump (7).
Connect plastic tube assembly (11) to fuel filter base (12) and fuel injection pump (7). Install plastic tube assembly (11) to clip (9).
Remove the plug from fuel filter base (12). Remove the cap from plastic tube assembly (3).
Connect plastic tube assembly (3) to fuel injection pump (7).
Position a new sealing washer (4) (not shown) onto banjo bolt (5). Install banjo bolt (5) onto plastic tube assembly (3) and install the remaining new sealing washer (4) (not shown).
Install plastic tube assembly (3) to clip (8) and clip (9).
Tighten banjo bolt (5) to a torque of 21 N m (186 lb in).
Connect hose assembly (6) to the connection on plastic tube assembly (3).
Connect hose assembly (2) to the fuel injector. Install plastic tube assembly (3) to clip (3).
Install clip (10) to plastic tube assembly (3) and plastic tube assembly (11).
Turn the fuel supply to the ON position.
Remove the air from the fuel system. Refer to Operations and Maintenance Manual, "Fuel System - Prime".