90816A25 Mercury CABLE, HIGH TENSION

Table 1
Required Tools(1)
Tool Part Number Part Description Qty
ZZ 9U-7067 Cap 4
9U-7069 Cap 4
(1) SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.Start By:
Remove the cover for the fuel injection nozzles. Refer to this Disassembly and Assembly Manual, "Fuel Injection Nozzle Cover - Remove and Install".
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.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.
Illustration 1 g01135845
Typical example
Disconnect the fuel injection lines (2) at the fuel injection nozzles (1).
Disconnect the fuel injection lines (4) at the fuel injection pump (6). Ensure that the connections (5) do not turn when the fuel injection lines are removed.
Illustration 2 g01136262
Typical example
If it is necessary, remove the clamps (3) for the fuel injection lines or loosen the clamps for the fuel injection lines. Remove the fuel injection lines.
Install dust caps onto the ports of the fuel injection nozzles and onto the ports of the fuel injection pump. Install dust caps onto both ends of the fuel injection lines. Installation 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.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.
Illustration 3 g01135845
Typical example
Inspect the fuel injection lines (2 and 4) for wear and for damage. Replace any fuel injection line (1) that is worn or any fuel injection line that is damaged.
Loosely install the clamps (3) for the fuel injection lines.
Remove the dust caps from the fuel injection pump (6) and from the fuel injection nozzles (1). Remove the dust caps from the fuel injection lines (1).
Illustration 4 g01136262
Loosely connect the nuts at both ends of the fuel injection lines.
Ensure that each fuel injection line does not contact any other fuel injection line or any other engine component. Tighten the fasteners for the clamps (3) for the fuel injection lines . Check that the fuel injection lines are still clear of other components.
Tighten the fuel injection lines (2) at the fuel injection nozzles (1) to a torque of 30 N m (22 lb ft).
Tighten the fuel injection lines (5) at the fuel injection pump (6) to 30 N m (22 lb ft). Ensure that the connection (5) can not turn.
Remove the air from the fuel system. Refer to the Operations and Maintenance Manual, "Fuel System - Prime". End By:
Install the cover for the fuel injection nozzles. Refer to this Disassembly and Assembly Manual, "Fuel Injection Nozzle Cover - Remove and Install".