809088T Mercury PUMP KIT, Fuel

Illustration 1 g06458062
If necessary, follow Step 1a through Step 1h to remove and disassemble the cross over pipe assembly.
Make temporary marks on the tube assembly for installation purposes only.
Sufficiently loosen hose clamp (8), position the hose clamp away from throttle valve assembly (7).
Sufficiently loosen hose clamp (4), position the hose clamp away from turbocharger (3).
Sufficiently loosen hose clamp (6), position the hose clamp away from hose (9).
Sufficiently loosen hose clamp (1), position the hose clamp away from hose (2).
Position hose (2) away from turbocharger (3).
Remove tube assembly (5) from throttle valve assembly (7).
Remove hose (9) and hose (2) from tube (5).
Illustration 2 g06458088
If necessary, cut cable strap (17) and cable strap (20).
If necessary, disconnect engine harness (18) from throttle valve (19).
Disconnect engine harness (14) from inlet manifold temperature and pressure sensor (15).
If necessary, remove nut (11) and spring washer (13) (not shown) from engine harness (12).
If necessary, remove bolts (10) from bracket (21). Remove the bracket from the engine harness assembly (12). Position the harness assembly away from inlet manifold temperature and pressure sensor (15).
Remove bolt (16) from inlet manifold temperature and pressure sensor (15). Remove the inlet manifold temperature and pressure sensor from the bracket by pulling up by hand with a slight twisting motion.Note: Do not lever the inlet manifold temperature and pressure sensor out of the bracket.Discard inlet manifold temperature sensor.
Illustration 3 g06458349
If necessary, using a suitable tool compress the hose clamp (22). Position the hose clamp away from bracket (25). Note the position of the hose clamp for installation purposes.
If necessary, remove hose (23) from bracket (25).
If necessary, remove bolts (24) and remove bracket (25) from throttle valve assembly (7).
If necessary, remove the NOx reduction system (NRS) cooler. Refer to Disassembly and Assembly, "Exhaust Cooler (NRS) - Remove and Install" for the correct procedure.
Illustration 4 g06458353
If necessary, make temporary marks on hose (23) and the cylinder head for installation purposes.
If necessary, using a suitable tool compress hose clamp (26). Position the hose clamp away from adaptor (28). Note the position of the hose clamp for installation purposes.
If necessary, remove hose (23) from adaptor (28). Remove the hose clamps from the hose.
If necessary, remove adaptor (28) from the cylinder head. Remove O-ring seal (27) (not shown).Installation Procedure
Note: Remove all plugs and caps as installation is completed.
Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
Illustration 5 g06458353
If necessary, install new O-ring seal (27) (not shown) to adaptor (28).
If necessary, install adaptor (28) to the cylinder head, tighten the adaptor finger tight.
if necessary, tighten adaptor (28) to a torque of 15 N m (133 lb in).
If necessary, install new hose clamps onto hose (23). Position the hose onto adaptor (28) in the position noted on removal.
If necessary, use a suitable tool to expand new hose clamp (26) and position the new hose clamp in the location noted on removal.Note: Ensure that the hose clamp is correctly orientated.
If necessary, install the NOx reduction system (NRS) cooler. Refer to Disassembly and Assembly, "Exhaust Cooler (NRS) - Remove and Install" for the correct procedure.
Illustration 6 g06458349
If necessary, position bracket (25) onto throttle valve assembly (7). Install bolts (24). Loosely tighten the bolts.
If necessary, tighten bolts (24) to a torque of 22 N m (195 lb in).
If necessary, install hose (23) onto bracket (25).
If necessary, use a suitable tool to expand new hose clamp (22) and position the new hose clamp in the location noted on removal.Note: Ensure that the hose clamp is correctly orientated.
Illustration 7 g06458088
Install new inlet manifold temperature and pressure sensor (15). Ensure that the inlet manifold temperature and pressure sensor is correctly installed to bracket (25).
Install bolt (16) to new inlet manifold temperature and pressure sensor (15). Loosely tighten the bolt.
Tighten bolt (16) to 8 N m (71 lb in).
If necessary, position bracket (21) onto engine harness (12). Install bolts (10). Loosely tighten the bolts.
If necessary, tighten bolts (10) to a torque of 22 N m (195 lb in).
If necessary, install spring washer (13) and nut (11) onto engine harness (12). Loosely tighten the nut.
If necessary, tighten nut (11) to a torque of 8 N m (71 lb in).
Connect engine harness (14) to inlet manifold temperature and pressure sensor (15).
If necessary, connect engine harness (18) to throttle valve (19).
If necessary, install new cable strap (17) and new cable strap (20).Note: Ensure that the cable straps meet the OEM specification.
Illustration 8 g06458062
If necessary, follow Step 22a through Step 22h to install and assemble the crossover pipe assembly.
Position hose (9) and hose (2) onto tube (5) in the positions noted on the removal.
Position new hose clamp (8), new hose clamp (6), new hose clamp (1), and new hose clamp (4) onto tube assembly (5).Note: Ensure that the hose clamps are correctly orientated.
Install hose assembly (5) onto throttle valve assembly (7) and turbocharger (3).
Position new hose clamp (8) onto hose (9) in the pos