804903001 Mercury GROMMET

Hot engine oil and components can cause personal injury. Do not allow hot engine oil or components to contact the skin. Be sure that the engine and components are cool enough to touch with your bare hand prior to performing any service work.
1. Disconnect tube assembly (1) and hose assembly (2) from the unit injector hydraulic pump. 2. Remove nut (4), the washers and bolt to separate hose assembly (3) from tube assembly (1). 3. Remove bolt (5) and the washer, and spacer and clamp (6) that holds tube assembly (1) to the engine. Remove tube assembly (1) with O-ring seal (7), not shown.
The fuel in the engine electronic control module and in the hose assemblies connected to the module may be under high pressure. When the hose assemblies connected to the module are disconnected, the pressure will be released. Fuel under high pressure can penetrate the body causing personal injury. To release the pressure, slowly loosen the hose assemblies from the module.
For photographic reasons, the aftercooler has been removed. Reference call outs 8 through 12 do not appear in this story. They were utilized in the aftercooler situation. Mark and identify all hose assemblies and tube assemblies connected to the unit injector hydraulic pump for installation purposes.4. Disconnect hose assembly (13). Cap and plug all openings immediately.5. Disconnect three tube assemblies (14). Cap and plug all openings immediately. 6. Cut tie-straps (15) and (16). 7. Disconnect rail pressure control valve (17) at the electrical connection.8. Mark and identify oil temperature sensor connector (18) and oil pressure sensor connector (19) for installation purposes. Disconnect oil temperature sensor connector (18) and oil pressure sensor connector (19) at the electrical connection. 9. Remove three bolts (20) and the washers. 10. Fasten a lifting sling and a hoist to unit injector hydraulic pump (21).11. Remove two bolts (22) and the washers. Remove unit injector hydraulic pump (21). Remove the O-ring seals. The weight of unit injector hydraulic pump (21) is approximately 30 kg (65 lb). The following steps are for the installation of the unit injector hydraulic pump. If a new engine electronic control control is to be installed,refer to the topic "Replacing The Electronic Control with a new ECU" in the 3408E & 3412E Engine Trouble shooting Module SENR1060.12. Replace all O-ring seals with new O-ring seals. 13. Fasten a lifting sling and a hoist to unit injector hydraulic pump (21). Position unit injector hydraulic pump (21) in its original location. The weight of unit injector hydraulic pump (21) is approximately 30 kg (65 lb). 14. Install two bolts (22) and the washers. 15. Install three bolts (20) and the washers. 16. Connect rail pressure control valve (17), oil temperature sensor connector (18) and oil pressure sensor connector (19) at the electrical connections as shown. Fasten the connections with new tie-straps (15) and (16).
Make sure the left bank tube assembly is installed to the lower pump port first. Tube assemblies (14) can possibly be reversed.
17. Connect three tube assemblies (14) and hose assembly (13) to the unit injector hydraulic pump as shown. 18. Put a new O-ring seal (7) (not shown) on tube assembly (1). Lubricate O-ring seal (7) and the bore lightly with engine oil. Position tube assembly (1) on the engine.19. Put clamp (6) in position on tube assembly (1). Install the spacer and bolt (5) and the washer. 20. Fasten tube assembly (1) and hose assembly (3) together with bolt, nut and washer (4). 21. Connect hose assembly (2) and tube assembly (1) to the unit injector hydraulic pump. Refer to the Operation & Maintenance Manual for all fluid capacities and the proper filling procedures.22. Open the fuel main supply valve. Prime the fuel system. Refer to the Operation & Maintenance Manual for the correct procedure on priming the fuel system.End By:a. install hood group