38470 Mercury TUBE, EXHAUST (LONG SHAFT)

Table 1
Tool    Part Number    Part Description    Qty    
A     131-3921     Puller Assembly     1    
B     4C-4057     Tube     1    
C     1U-5718     Vacuum Pump     1    
D     1U-5814     Bottle Assembly     1    Start By:
Evacuate the fuel system.
Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove".
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.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.
Evacuating Fuel From The Fluid Manifold
Prior to removing the injector, evacuate as much fuel as possible from the manifold.
Illustration 1 g00484352
(A) Top view. (B) Front view.
Remove the fuel line (1) that is routed from the T-connector on the front of the engine to the front of the manifold.
Place the loose end of the fuel line (1) into an appropriate container in order to collect the fuel.
Use an air gun with a rubber tip in order to evacuate the fuel with pressurized air.
Place the rubber tip of the air gun in the fuel line opening of the manifold.
Approximately 138 to 207 kPa (20 to 30 psi) of pressurized air should be enough to evacuate the fuel from both manifolds without damaging the injectors.
When the fuel in the system has been evacuated, reconnect the fuel line to the manifold.
Fuel and oil will still need to be removed from the cylinder after the injectors are removed.Removal Of The Injector
The injector tip was made very hard to provide a long life. This hardness also makes the tip brittle. Side loading during the installation or striking the tip against a hard object or dropping the injector can cause the tip to break or crack. Installing an injector with a cracked tip may result in major engine damage.
After removing the injector, a certain amount of fuel and oil runs down the cylinder. Most of the fuel must be removed before the injector is reinstalled in order to avoid the possibility of hydraulic lock and severe engine damage when the engine is next cranked. In order to minimize the amount of fuel running into the cylinder, the fuel supply shutoff valve should be closed before injector removal.
The injector must not be damaged when the injector is returned for a warranty. The injector must also be returned in the original protective packaging. The warranty or remanufacturing core credit may be reduced or denied if the injector is not returned in the original packaging. An injector with possible damage to the tip must be returned in the original package. The damaged injector must be clearly identified as having "possible tip damage".
Illustration 2 g00811184
(2) Terminals of wire harness (3) Bolts (4) Adapter (5) Injector jumper tube (6) Socket head cap screw (7) Bolt (8) Clamp (9) Injector (10) O-ring seal (11) Injector sleeve (12) O-ring seal
Close the shut off valve for the fuel supply.
Remove the valve cover assembly.
Illustration 3 g00811209
Mark the terminals of the wire harness (2) with the number of the cylinder. This will help to ensure correct reassembly.
Remove the terminals of the wire harness (2) for the unit injector.
Remove the bolts (3) from the injector jumper tube (5) . Remove socket head cap screws (6) from the adapter (4) . Remove the injector jumper tube (5) and adapter (4) .
Illustration 4 g00811215
Remove O-ring seals (13) and (14) . Remove the clamp bolt (7) and the clamp (8) .