802702 Mercury PLUG

Introduction
The correct installation of emissions critical components is vital to comply with the relevant emissions legislation. In addition, it is important to highlight the key assembly characteristics of other components that are transported loose. The assembly of the loose components is carried out by a representative of the customer.This Special Instruction is intended to be used in addition to the Service Manual. This document should be used as an assembly guide or a reference document when developing processes for production assembly facilities. Critical assembly characteristics such as tightening torques, component orientation, and assembly sequences must be followed to achieve the required product quality and emissions regulations.The Service Manual consists of the following manuals.
Operation and Maintenance Manual
Disassembly and Assembly
Troubleshooting
Systems Operation Testing and Adjusting
SpecificationsCaterpillar recommends that customers do not power on the ECM at all until all engine and aftertreatment sensors and wiring are installed correctly. Powering the ECM without the engine installed correctly may trigger diagnostic trouble codes and emissions inducement codes which will need to be resolved with the electronic service tool. Emissions inducement error codes will remain in the error memory for up to 40 hours of operation.Customers are permitted to paint the engine as received or as part of a power train sub assembly. These engines are supplied in gray primer.The customer is not permitted to paint the aftertreatment or exhaust systems, Electronic Control Module (ECM), starting motor, alternator, belts, or the glow plug control unit. The customer is also not permitted to paint any filters and filter canisters. The canisters include fuel, air, oil, crankcase breather, or DEF.The customer is required to develop suitable plugs and masks to a standard equivalent to that used in the engine assembly plant.The customer is required to prevent water ingress into the engine by maintaining a standard of plugging equivalent to that used in the engine assembly plant.Engine Air Cleaner
Illustration 1 g03179402
Typical example
The engine air cleaner (1) can be supplied as a loose assembly. The engine air cleaner should be mounted horizontally. The dust exhaust port should be at the lowest point and positioned in a direction that is down.Note: Do not paint the dust exhaust port. Solvents and chemicals will shorten the usable life of the exhaust port.Note: There are several variations of engine air cleaner.Select the appropriate sized fasteners for the relevant air cleaner. Bolts should have a flanged head or be installed with a washer under the bolt head.Standard duty air cleanerTighten the M8 bolts to the following torque. ... 22 N m (16 lb ft)
Illustration 2 g03415816
Typical example
The position of the clamp (2) in relation to pipe or component bead (3) is crucial. Ensure that clamp (2) are installed on the correct side of the pipe or component beads (3).Air Temperature Sensor
Illustration 3 g03227717
Typical example
Install the sensor (1). Tighten the sensor to a torque of 20 3 N m (177 27 lb in).Installation of the Fan
Illustration 4 g03242856
Typical example
Remove alternator belt.
Install studs (3) to fan drive (1). Tighten studs to a torque of 11 3 N m (97 27 lb in)
Install fan drive pulley (2) to fan drive (1).
Install alternator belt.
Install fan adapter (4) to studs (3).
Install fan (5) to studs (3).
Install nuts (6) to studs (3). Tighten nuts to a torque of 22 5.5 N m (195 49 lb in)
Ensure that alternator belt is the correct tension. Refer to "Installation of Alternator and Fan Belts" for the correct procedure.Installation of the Fan (Engines without a Fan Drive)
Remove alternator belt.
Remove the bolts for the fan pulley. Remove fan pulley.
Install studs. Tighten studs to a torque of 11 3 N m (97 27 lb in)
Install fan drive pulley to studs.
Install alternator belt.
Install fan adapter to studs.
Install fan to studs.
Install nuts to studs. Tighten nuts to a torque of 22 5.5 N m (195 49 lb in)
Ensure that alternator belt is the correct tension. Refer to "Installation of Alternator and Fan Belts" for the correct procedure.Installation of Alternator and Fan Belts
In certain instances, the OEM may need to install the alternator and fan belts to the engine.If the customer is receiving engines with different fan pulley diameters and is installing belts of different lengths, the customer must be able to demonstrate that a belt of correct length is being assembled to an individual engine.
Illustration 5 g02553437
Typical example
Ensure that the pulleys and guide rollers are free from dirt debris, and paint.
Install new alternator belt (6) onto