824012 Mercury ROLLER

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.
When the fuel pressure relief valve is removed, a new fuel pressure relief valve must be installed.
Illustration 1 g03377176
Disconnect the hose assembly from inlet connection (1).
Thoroughly clean the area around fuel manifold (2) and fuel pressure relief valve (1).
Remove bolts (4) from inlet connection (1).
Remove inlet connection (1) and gasket (3) (not shown) from the inlet manifold.
Follow Step 6.a through Step 6.d in order to remove fuel pressure relief valve (5) from fuel manifold (2).
Ensure that the area around the fuel pressure relief valve (5) and fuel manifold (2) is still thoroughly clean.
Remove fuel pressure relief valve (5) from fuel manifold (2).
Immediately use tooling (A) to cap the open port in fuel manifold (2).
Immediately use Tooling (A) to cap the fuel pressure relief valve (5). Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
B - Bosch Grease Ft1v27 1
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 g03442338
Follow Step 1.a through Step 1.h in order to install a new fuel pressure relief valve (5) to fuel manifold (2).
Remove the cap from the port in fuel manifold (2).
Immediately clean the threads in fuel manifold (2) for fuel pressure relief valve (5). Ensure that the thread is clean and free from debris. Ensure that the thread in the fuel manifold (2) is free from damage.
Immediately use Tooling (A) to cap the open port in fuel manifold (2) after cleaning and inspection.
Remove the cap from the threaded end of fuel pressure relief valve (1). Lightly lubricate the thread and bite edge (6) of the pressure relief valve with Tooling (B).
Inspect the O-ring seal on the new fuel pressure relief valve (5) for damage. Replace the fuel pressure relief valve as an assembly if the O-ring seal is damaged.
Remove the cap from the port of fuel manifold (2). Install fuel pressure relief valve (1) into fuel manifold (2) hand tight.
Tighten fuel pressure relief valve (1) to a torque of 100 N m (74 lb ft).
Clean excessive Tooling (B) from fuel pressure relief valve (1) and fuel manifold (2).
Clean the gasket surfaces of the inlet connection (1) and the inlet manifold.
Position a new gasket (3) (not shown) onto inlet connection (1).
Position inlet connection (1) onto the inlet manifold.
Install bolts (4) to inlet connection (1). Tighten the bolts to a torque of 22 N m (195 lb in).
Connect the hose assembly to inlet connection (1). Securely tighten hose clamp.
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.