803755006 Mercury TUBE, Water

Hot engine oil and components can cause personal injury. Do not allow hot engine oil or components to contact the skin. Be sure that the engine and components are cool enough to touch with your bare hand prior to performing any service work.
1. Remove two nuts (1), four bolts (3), and lifting bracket (2). 2. Disconnect fuel temperature sensor connector (4) at the electrical connection. 3. Disconnect atmospheric pressure sensor connector (10) and turbocharger outlet pressure sensor connector (8) at the electrical connections.4. Cut tie-strap (7). Disconnect hose assemblies (5), (6) and (11) and remove the O-ring seals. Cap and plug all openings immediately.5. Remove nut, washer and clip (9). 6. Mark and identify bolts (13) for installation purposes. Remove ten bolts (13), two nuts (15) and the washer that hold cover (12) to the unit injector hydraulic pump drive. Remove cover (12) and gasket (14) (not shown). 7. Remove four bolts (17), retainer plate (18) and gear (16). 8. Remove both timing sensors (20). Remove four mounting bolts (21), pin (22) and the seal. Remove two bottom bolts (23), and remove unit injector hydraulic pump drive (19). 9. Remove O-ring seals (24) from unit injector hydraulic pump drive (25). The following steps are for the installation of the unit injector hydraulic pump drive. Replace all O-ring seals and gaskets used in the removal procedure with new parts. 10. Place O-ring seals (24) in position on unit injector hydraulic pump drive (25).11. Lubricate the bore of the front housing and the seal on the unit injector hydraulic pump drive lightly with clean engine oil. Put unit injector hydraulic pump drive (25) in position in the front housing. 12. Install two bolts (23).13. Install four mounting bolts (21) and pin (22) and the seal. Tighten bolts (21) to a torque of 5 3 N m (4 2 lb ft). Tighten locating pin (22) to a torque of 105 10 N m (75 7 lb ft). Retighten mounting bolts (21) to a torque of 55 7 N m (40 5 lb ft).14. Put gear (16) in position on the unit injector hydraulic pump drive. Install retainer plate (18) with four bolts (17). Tighten four bolts (17) to a torque of 135 20 N m (100 15 lb ft). With number one piston at top center, align timing mark (H) on gear (16) with timing mark (H) on the camshaft gear. For complete details regarding positioning the number one piston at top center, see the topic "Finding Top Center Compression Position For Number One Piston" in the Systems Operation Testing & Adjusting Manual module, SENR1018. The timing sensor ends are retractable and must be fully extended before they are installed.15. Install both timing sensors (20). Tighten timing sensors (20) to a torque of 40 5 N m (29 4 lb ft). 16. Clean the mating surfaces of the front housing and cover (12). Install a new gasket (14) and cover (12) and secure with bolts (13), two nuts (15) and the washer. 17. Install clip (9) the washer and the nut. Connect atmospheric pressure sensor connector (10) and turbocharger outlet pressure sensor connector (8) at the electrical connections.18. Install new O-ring seals (not shown) in hose assemblies (11), (6) and (5), and connect hose assemblies (11), (6) and (5). Install a new tie-strap (7). 19. Connect fuel temperature sensor connector (4) at the electrical connection. 20. Install lifting bracket (2). Fasten to engine with four bolts (3) and two nuts (1).End By:a. install unit injector hydraulic pump