803924 Mercury SPRING

Introduction
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.Before replacing any C9.3 high-pressure fuel line, follow the instructions that are listed below.Note: The following procedures were written for the complete removal of all of the fuel lines and clamps. If only specific fuel lines need to be replaced, then only remove the fuel lines and clamps that need replacement.Note: Failure to follow this procedure may result in a leaking fuel line.Safety Section
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.
Contact with high pressure fuel may cause personal injury or death. Wait 60 seconds after the engine has stopped to allow fuel pressure to purge before any service or repair is performed on the engine fuel lines.
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.Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Fuel injection lines MUST only be used once. Discard all fuel injection lines after use.
Fuel Line Removal and Installation Procedures
Required Parts
Table 1
Part Number     Line Designation     Description    
356-0828     Cylinder 1 fuel line     Fuel Lines Kit    
356-5217     Cylinders 2,3, and 4 fuel line     Fuel Injection Line Assembly    
356-0832     Cylinders 5 and 6 fuel line     Fuel Lines Kit    
356-0831     Fuel pump to rail line     Fuel Lines Kit    Replace the removed high-pressure fuel line with the corresponding Fuel Lines Kit. The clamp, the grommet, and the new fuel line that is supplied with the Fuel Lines Kit must be used as the replacements for the old parts. Refer to Table 1.Note: Do not reuse the old clamp, the old grommet, and the old fuel line.Removal Procedure
Turn the fuel supply to the OFF position.
Disconnect the battery. Refer to Operation and Maintenance Manual, "Battery or Battery Cable - Disconnect".
Remove all components in order to access to the wiring harness.
Illustration 1 g02140798
Loosen clamp assemblies (1) and remove hose (2) .
Illustration 2 g02140852
Disconnect fittings (3) and (7) .
Remove bolts (5), (6), and (8) and remove tube assembly (4) .
Remove bolt (9) .
Illustration 3 g02140971
Remove nuts (10) and remove bracket (11) .
Disconnect harness assemblies (12) .
Illustration 4 g02141119
Position harness assembly (13) out of the way. Remove the spacers (not shown) from studs (14) .
Illustration 5 g02241493
Remove the bolt (15) and remove the clamp assembly. Discard the clamp assembly.
Remove nuts (23), (19), and (20). Remove the corresponding clamp assemblies and discard the clamp assemblies.
Loosen nuts (16) and (18). Remove fuel line (17) and discard the fuel line. Repeat for the remaining fuel lines.
Loosen nuts (21) and (24). Remove fuel line (22) and discard the fuel line.Installation Procedure
Fuel injection lines MUST only be used once. Discard all fuel injection lines after use.