5031163 JOHNSON BOLT (12X117mm)

Table 1
Required Tools
Tool Part Number Part Description Qty
A 388-1289 Capping Kit 1
B - LASER 4920
1/2 Inch Drive HP Fuel Line Socket Set 1
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.
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
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.Dispose of all fluids according to local regulations and mandates.
Note: Put identification marks on all hoses on all hose assemblies and on wires and all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. Plugging all hose assemblies and tube assemblies will help to prevent fluid loss and helps to keep contaminants from entering the system.
Turn the fuel supply to the OFF position.
Turn the battery disconnect switch to the OFF position.
If necessary, remove the Clean Emissions Module (CEM). Refer to Disassembly and Assembly, "Clean Emissions Module - Remove" for the correct procedure.
Illustration 1 g03774865
Illustration 2 g02683476
Disconnect the Original Equipment Manufacturers (OEM) wiring harness assembly from connection (5) and connection (8).
Open cable support clamps (1) from the wiring harness assemblies.
Slide the locking tab for wiring harness assembly (3) into the unlocked position. Disconnect wiring harness assembly (3) from pressure sensor (2).
Disconnect wiring harness assembly (14) from oil pressure switch (13).
If necessary, cut cable straps in order to remove the wiring harness assemblies.
Slide the locking tab for wiring harness assembly (15) into the unlocked position. Disconnect wiring harness assembly (15) from crankshaft position sensor (16).
Slide the locking tab for wiring harness assembly (17) into the unlocked position. Disconnect wiring harness assembly (17) from camshaft position sensor (18).
Slide the locking tab for wiring harness assembly (9) into the unlocked position. Disconnect wiring harness assembly (9) from the fuel metering valve (10).
Disconnect the wiring harness assembly from fuel temperature sensor (4).
Remove bolt (6) from wiring harness assembly (11).
Position the wiring harness assembly (11) away from fuel injection lines (12).
Illustration 3 g02848956
Illustration 4 g03775330
If necessary, remove the fuel filter base mounting bracket (21) (not shown). Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install" for the correct procedure.
Remove bolt (23) from tube clamp (22). Remove tube clamp (22) from fuel injection lines (12). Note: Make temporary marks to identify the position of the tube clamps.
Repeat Step 16 in order to remove the remaining tube clamps.
Remove bolt (26). Remove bracket (25) from the valve mechanism cover.
Clean the area around the nuts for fuel injection lines (12). Ensure that the area is free from contamination before beginning disassembly.
Use Tooling (B) in order to disconnect fuel injection line (12) from the electronic unit injector (27).
Use Tooling (B) in order to disconnect fuel injection line (12) from fuel manifold (24).
Remove fuel injection line (12). Discard the fuel injection lines.
Use Tooling (A) in order to cap all open ports immediately in fuel manifold (24) and electronic unit injectors (27).
Repeat Step 19 through Step 23 in order to remove the remaining fuel injection lines from the fuel manifold to the electronic unit injectors.
Illustration 5 g03829598
Clean the area around the nuts for fuel injection line (28). Ensure that the area is free from contamination before beginning disassembly.
Remove bolt (30) from the bracket for fuel injection line (28).
Disconnect fuel injection line (28) from fuel injection pump (29).
Disconnect fuel injection line (28) from fuel manifold (24).
Remove fuel injection line (28). Discard the fuel injection line.
Use Tooling (A) in order to cap all open ports immediately in fuel manifold (24) and in fuel injection pump (29).