804520 Mercury FITTING (AIR/FUEL) STARBOARD

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     422-7170     Capping Kit     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.
Turn the fuel supply to the OFF position.
Illustration 1 g02688080
Place a suitable container below the fuel filter base in order to catch any fuel that might be spilled. Remove fuel filters (11) . Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure.
Make temporary identification marks on plastic tube assembly (1) , plastic tube assembly (4) , and plastic tube assembly (10) in order to show the correct position of the tube assemblies.
Remove tube clip (9) from plastic tube assembly (1) and plastic tube assembly (10) .
Disconnect plastic tube assembly (4) from fuel filter base (5) . Use Tooling (A) to cap the connection for plastic tube assembly (4) .
Use Tooling (A) to cap plastic tube assembly (4) .
Disconnect plastic tube assembly (10) from fuel filter base (5) . Use Tooling (A) to plug fuel filter base (5) .
Use Tooling (A) to cap plastic tube assembly (10) .
Remove banjo bolt (3) and sealing washers (2) (not shown). Disconnect plastic tube assembly (1) from fuel filter base (5) .
Use Tooling (A) to cap plastic tube assembly (1) .
Use Tooling (A) to plug fuel filter base (5) .
Disconnect tube assembly (8) from fuel filter base (5) .
Remove the nuts and bolts (6) from fuel filter base (5) . Remove fuel filter base (5) from the mounting bracket. Use Tooling (A) to plug fuel filter base (5) .Note: Do not disassemble the fuel filter base.
Remove seal (7) (not shown) from fuel filter base (5) . Use Tooling (A) to cap tube assembly (8) .
Illustration 2 g02688081
If necessary, remove the mounting bracket for the fuel filter from the cylinder head. Follow Step 15.a through Step 15.b in order to remove the mounting bracket for the fuel filter.
Remove bolts (14) and bolt (15) from mounting bracket (13) .
Remove mounting bracket (13) from cylinder head (12) .Note: Place temporary identification on mounting bracket in order to show the correct orientation Installation Procedure
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.
Illustration 3 g02688081
If necessary, install the mounting bracket for the fuel filter to the cylinder head. Follow Step 1.a through Step 1.c in order to install the mounting bracket for the fuel filter.
Position mounting bracket (13) onto cylinder head (12) .Note: Ensure that the mounting bracket is correctly orientated.
Install bolts (14) and bolt (15) to mounting bracket (13) .
Tighten bolts (14) to a torque of 22 N m (195 lb in).Tighten bolts (15) to a torque of 44 N m (32 lb ft).
Illustration 4 g02688080
Ensure that fuel filter base (5) is clean and free from damage. If necessary, replace the complete fuel filter base and filter assembly.
Remove the cap from tube assembly (8) .
Remove the plug from fuel filter base (5) . Install a new seal (7) (not shown) to fuel filter base (5) .
Position fuel filter base (5) onto the mounting bracket.
Connect tube assembly (8) to fuel filter base (5) .
Install the nuts and bolts (6) to fuel filter base (5) finger tight.
Tighten the nuts and bolts (6) to a torque of 44 N m (32 lb ft).
Tighten the nut for tube assembly (8) to a torque of 23 N m (204 lb in).
Ensure that the plastic tube assemblies are installed in the original positions. Failure to connect the plastic tube assemblies to the correct ports will allow contamination to enter the fuel system. Fuel contaminated will result in serious damage to the engine.
Remove the cap from plastic tube assembly (10) . Connect plastic tube assembly (10) to fuel filter base (5) .
Remove cap from plastic tube assembly (1)
Remove the plug from fuel filter base (5) .
Position plastic tube assembly (1) onto fuel filter base (5) .
Position a new sealing washer (2) (not shown) onto banjo bolt (3) . Install banjo bolt (3) onto plastic tube assembly (1) and install the remaining new sealing washer (2) (not shown).
Tighten ba