859169T Mercury STARTER MOTOR ASSEMBLY

Table 1
Required Tools
Tool Part Number Part Description Qty
A 370-8376 Cap Kit 1
Turn the fuel supply to the OFF position.
Turn the battery disconnect switch to the OFF position.
Illustration 1 g02237434
Make temporary identification marks on hose tube assemblies in order to show the correct position of the hose tube assemblies. Making temporary identification marks on the hose assemblies will ensure that the hose assemblies are installed in the original positions.
Disconnect hose assembly (2) and remove O-ring seal (3) (not shown). Use Tooling (A) in order to cap the connection on the ARD fuel pump. Use Tooling (A) in order to cap the hose assembly.
Disconnect hose assembly (5) and hose assembly (8). Use Tooling (A) in order to cap the connections on the ARD fuel pump. Use Tooling (A) in order to plug the hose assemblies
Slide the locking tab for harness assembly (1) for ARD fuel pump (4) into the unlocked position. Disconnect Original Equipment Manufactures (OEM) harness assembly from harness assembly (1) for ARD fuel pump (4).
Remove bolts (6) and washers (7) from ARD fuel pump (4).
Remove ARD fuel pump (4) from the mounting bracket.
Illustration 2 g02237435
If necessary, follow Step 9.a through Step 9.f in order to disassemble fuel pump (4) for the ARD.
Remove connection (9) and remove O-ring seal (10) (not shown).
Remove connection (16) from adaptor (11). Remove O-ring seal (15) (not shown).
Remove connection (17) from adaptor (19). Remove O-ring seal (18) (not shown).
Make temporary identification marks on adaptor (11) in order to show the correct orientation. Remove adaptor (11) and remove O-ring seal (12) (not shown).
Remove adaptor (19) and remove O-ring seal (20) (not shown).
Remove isolation mounts (13) and limit sleeve (14) from ARD fuel pump (4). Installation Procedure
Ensure that all components for ARD fuel pump are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
Illustration 3 g02237435
If necessary, follow Step 2.a through Step 2.f in order to assemble ARD fuel pump (4).
Install a new O-ring seal (10) (not shown) to connection (9). Install connection (9) to ARD fuel pump (4). Tighten the connection to a torque of 25 N m (221 lb in).
Install a new O-ring seal (12) (not shown) to adaptor (11). Install adaptor (11) to ARD fuel pump (4). Tighten the adaptor to a torque of 25 N m (221 lb in). Note: Ensure that the adaptor is correctly orientated.
Install a new O-ring seal (15) (not shown) to connection (16). Install connection (16) to adaptor (11). Tighten the connection to a torque of 25 N m (221 lb in).
Install a new seal washer (20) (not shown) to adaptor (19). Install adaptor (19) to ARD fuel pump (4). Tighten the adaptor to a torque of 25 N m (221 lb in).
Install a new O-ring seal (18) (not shown) to connection (17). Install connection (17) to adaptor (19). Tighten the connection to a torque of 15 N m (133 lb in).
Install isolation mounts (13) and limit sleeve (14) to ARD fuel pump (4).
Illustration 4 g02237434
Position ARD fuel pump (4) onto the mounting bracket.
Install bolts (6) and washers (7) to ARD fuel pump (4). Tighten bolts to a torque of 22 N m (195 lb in).
Install a new O-ring seal (3) (not shown) to the connection on ARD fuel pump (4). Connect hose assembly (2) and securely tighten hose assembly Note: Ensure that the hose assembly is installed in the original position.
Connect hose assembly (5) and hose assembly (8). Note: Ensure that the hose assemblies are installed in the original positions.
Connect the OEM harness assembly to harness assembly (1) on ARD fuel pump (4). Slide the locking tab for harness assembly (1) for ARD fuel pump (4) into the locked position.
Turn the battery disconnect switch to the ON position.
Turn the fuel supply to the ON position.