804281T Mercury RELAY

Table 1
Required Tools
Tool Part Number Part Description Qty
A 370-8376 Capping Kit 1 Start By:
If necessary, remove the secondary fuel filter and the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install" for the correct procedure.
If necessary, remove the water separator and fuel filter (Primary). Refer to Disassembly and Assembly, "Water Separator and Fuel Filter (Primary) - Remove and Install" for the correct procedure.
Remove the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install" for the correct procedure.
Remove the crankcase breather canister and plastic tube assemblies. Refer to Disassembly and Assembly, "Crankcase Breather - Remove" for the correct procedure.
Remove the fuel manifold. Refer to Disassembly and Assembly, "Fuel Manifold (Rail) - Remove and Install" for the correct procedure.
Remove the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove" for the correct procedure.
Remove the mounting bracket for the electronic control module. Refer to Disassembly and Assembly, "ECM Mounting Bracket - Remove and Install" for the correct procedure.
Remove the glow plugs. Refer to Disassembly and Assembly, "Glow Plugs - Remove and Install" for the correct 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.Dispose of all fluids according to local regulations and mandates.
Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct draining procedure.
Illustration 1 g02005213
Disconnect the upper radiator hose from water temperature regulator housing (1) on the cylinder head.
Illustration 2 g02206193
Remove plastic tube assembly (2), plastic tube assembly (3), and plastic tube assembly (7) from clips (9).
Cut all cable straps (5) from engine wiring harness assembly (6). Position engine wiring harness assembly away from the engine. Note: Ensure that all cable straps are removed from the engine wiring harness.
Remove bolts (8) and remove bracket (4) from the cylinder head.
Illustration 3 g02206194
Follow Step 6.a through Step 6.b in order to disconnect harness assembly (15) from boost pressure sensor (13).
Slide locking tab (14) into the unlocked position.
Disconnect harness assembly (15) from boost pressure sensor (13).
Follow Step 7.a through Step 7.b in order to disconnect harness assembly (11) from inlet air temperature sensor (10).
Slide locking tab (12) into the unlocked position.
Disconnect harness assembly (11) from inlet air temperature sensor (10).
Remove all cable straps that secure the harness assembly to the cylinder head. The harness assembly should be positioned away from the cylinder head in order to avoid causing an obstruction during the removal of the cylinder head.
On some application there is an engine wiring harness support bracket on the rear of the cylinder head. if necessary, cut the cable straps and remove the engine wiring harness from the support bracket. Remove the support bracket from the cylinder head before removal the cylinder head assembly.
Illustration 4 g02206213
Remove bolt (16) from tube assembly (18). Remove bolt (20) from tube clip (19).
Remove tube assembly (18) from the cylinder head. Remove O-ring seal (17) (not shown) from the tube assembly. Plug the port in the cylinder head with a new plug. Cap the tube assembly with new cap.
Illustration 5 g02206214
Follow Step 12.a through Step 12.c in order to disconnect harness assembly (22) from coolant temperature sensor (23).
Slide locking tab (21) into the unlocked position.
Disconnect harness assembly (22) from coolant temperature sensor (23).
Cut cable strap (26) and remove harness assembly (22) from bypass tube (25).
Remove bolts (24).
Remove bypass tube (25) from the cylinder head. Remove O-ring seal (27) and O-ring seal (28) from bypass tube (25).
Illustration 6 g02206215
Illustration 7 g03417150
Sequence for tightening the bolts for the cylinder head
Gradually loosen bolts (29) in the reverse numerical order to the tightening sequence. Refer to the Illustration 7. Note: Follow the correct sequence in order to help prevent distortion of the cylinder head.
Remove bolt