81
CD803
REPLACING WATER SEPARATING FUEL FILTER
CAUTION
Any water entering the fuel injection system will disable the system. Check for water in water
separating fuel filter before startup, daily.
CAUTION
If water should enter the fuel injection system, take unit to an Authorized Mercury MerCruiser Dealer
IMMEDIATELY, so that corrosion and rusting of the injectors and other components can be avoided.
WARNING
Be careful when changing water separating fuel filter. Diesel fuel is flammable. Be sure ignition key is
OFF. Do not allow fuel to contact any hot surfaces which may cause it to ignite. Do no tallow sources
of open flame in the area. Wipe up any spilled fuel immediately. Dispose of fuel soaked rags, paper,
etc. in an appropriate air tight, fire retardant container. Fuel soaked items may spontaneously ignite
and result in a fire hazard which could cause serious bodily injury or death.
IMPORTANT: Element cannot be cleaned and reused. It must be replaced.
1 Remove water separating fuel filter and sealing ring from fuel filter bracket.
2 Remove the drain cap from the filter by turning it counterclockwise. Discard the used filter.
3 Install the O-ring and drain cap on the new fuel filter. Tighten drain cap.
4 Clean filter sealing surface on mounting bracket.
5 Coat sealing ring on new filter with clean motor oil.
6 Thread filter onto bracket until the sealing ring contacts bracket.
7 Tighten the fuel filter an additional 2/3 of a turn with a filter wrench.
8 Ensure bottom drain cap is securely tightened. Fill fuel filter as explained previously. Check filter and drain
cap for fuel leaks.
WARNING
Make sure no leaks exist before closing engine hatch.
9 Start and run engine. Check filter connection for fuel leaks. If leaks exist, recheck filter installation. If leaks
continue, stop engine immediately and contact your Authorized Mercury MerCruiser Dealer.
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