803535002 Mercury PLUNGER

Fluid Spillage Containment
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "Tools And Shop Products Guide", NENG2500 for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose of fluids according to local regulations and mandates. Mark and identify all tube assemblies for installation purposes. Cap and plug all tube assemblies to avoid system contamination.1. Turn the fuel supply valve, located on the fuel tank, to the "Off" position. 2. Position a suitable container under fuel filter assemblies (1) to contain any fuel lost for storage or disposal. Using Tool (A) (not shown), remove two fuel filter assemblies (1). 3. Disconnect pressure switch wiring harness (2) at the electrical connection. Disconnect two tube assemblies (3) and (5) from pump adapter (4). 4. Disconnect tube assembly (7) from fuel filter base assembly (6). 5. Remove three bolts (8) and the washer that hold fuel filter base assembly (6) to the engine. Remove fuel filter base assembly (6) from the engine. The following steps are for the installation of the fuel filter base assembly. 6. Put fuel filter base assembly (6) in position on the engine. Install three bolts (8) and the washers that hold fuel filter base assembly (6) to the engine. 7. Connect tube assembly (7) to fuel filter base assembly (6). 8. Connect two tube assemblies (5) and (3) to pump adapter (4). Connect pressure switch wiring harness (2) at the electrical connection. 9. Clean the mating surfaces of fuel filter assemblies (1) prior to installation of fuel filter assemblies (1).10. Apply clean diesel fuel to the seals of each fuel filter assembly (1).11. Install two new fuel filter assemblies (1), by hand. When the seals of fuel filter assemblies (1) make contact with the fuel filter bases, use Tool (A) (not shown) to tighten fuel filter assemblies (1) three-quarters of a turn more. There are rotating-index marks 90 degrees apart on fuel filter assemblies (1). Use the marks as a guide for proper tightening.12. Turn the fuel supply valve, located on the fuel tank, to the "On" position.End By:a. install fuel priming pumpDisassemble & Assemble Fuel Filter Base Assembly
Start By:a. remove fuel filter base assembly 1. Remove six bolts (2) and the washers from support assembly (3). Remove support assembly (3) from filter base (1). 2. Remove four bolts (8), the nuts, and the washers that hold fuel filter base (5) to fuel filter base (6). Remove four bolts (7) and the washers that hold fuel filter base (5) to pump adapter (4).3. Remove pump adapter (4) and O-ring seals (9) from fuel filter base (5). Remove fuel filter base (5) and O-ring seals (10) from fuel filter base (6). Remove pressure switch assembly (11) and O-ring seals (7) and (8) from pump adapter (4). Remove O-ring seals (7) and (8) from pressure switch assembly (11). The following steps are for the assembly of the fuel filter base. Inspect all O-ring seals for wear or damage and replace if necessary. 4. Install O-ring seals (7) and (8) on pressure switch assembly (11). Install pressure switch assembly (11) in pump adapter (4). Tighten pressure switch assembly (11) to a torque of 52.5 5 N m (39 4 lb ft).5. Install O-ring seals (9) and (10) to fuel filter base (5). Position pump adapter (4) on fuel filter base (5). Install four bolts (7) and the washers that hold fuel filter base (5) to pump adapter (4).6. Position fuel filter base (5) to fuel filter base (6). Install four bolts (8), the nuts, and the washers that hold fuel filter base (5) to fuel filter base (6). 7. Put support assembly (3) in position on fuel filter base (1). Install six bolts (2) and the washers.End By:a. install fuel filter base assembly