9615A01 Mercury PISTON ASSEMBLY

Table 1
Required Tools
Tool Part Number Part Description Qty
A 370-8376 Capping Kit 1
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
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 1 g02276015
Typical example
Thoroughly clean the area around fuel manifold (2) and fuel pressure relief valve (1).
Disconnect the plastic tube assembly from fuel pressure relief valve (1) on fuel manifold (2). Use Tooling (A) in order to immediately cap the open port in fuel manifold (2) with a new cap. Tooling (A) in order to immediately plug the open end of the plastic tube assembly with a new plug.
Follow Step 3.a through Step 3.c in order to remove the fuel pressure relief valve from the fuel manifold.
Ensure that the area around the fuel pressure relief valve (1) and fuel manifold (2) is still thoroughly clean.
Use a deep socket in order to remove the fuel pressure relief valve (1) from fuel manifold (2).
Immediately cap the open port in fuel manifold (2) with a new cap. Immediately plug and cap the fuel pressure relief valve (1) with new plug and cap. 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 2 g02276015
Typical example
Follow Step 1.a through Step 1.g in order to install the fuel pressure relief valve to the fuel manifold.
Remove the cap from the port in fuel manifold (2).
Immediately clean the threads in fuel manifold (2) for fuel pressure relief valve (1). Ensure that the thread is clean and free from debris. Ensure that the thread in the fuel manifold (2) is free from damage.
Immediately cap the open port in fuel manifold (2) with a new cap after cleaning and inspection.
Remove the cap from the threaded end of fuel pressure relief valve (1). lubricate the thread of the pressure relief valve with clean fuel.
Remove the cap from the port of fuel manifold (2). Use a deep socket in order to install the fuel pressure relief valve (1) into fuel manifold (2) hand tight.
Tighten the fuel pressure relief valve to a snug torque of 30 N m (266 lb in). Rotate the fuel pressure relief valve in a clockwise direction for an additional 24 degrees in order to achieve the final torque.
Remove the cap from fuel pressure relief valve (1) for the plastic tube assembly. Connect the plastic tube assembly to fuel pressure relief valve (1).
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.