5036865 JOHNSON *COVER - Electric start

Table 1
Required Tools
Tool Part Number Part Description Qty
A 370-8376 Capping Kit 1 Start By:
Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove" for the correct procedure.
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.
Illustration 1 g03584583
Thoroughly clean the area around fuel manifold (2).
Disconnect harness assembly (4) from fuel pressure sensor (3).
Remove banjo bolt (1) from tube assembly (5).
Remove sealing washers (7) (not shown).
Immediately use Tooling (A) to cap the open port in fuel manifold (2). Immediately use Tooling (A) to plug the open end of tube assembly (5).
Remove bolts (8) from fuel manifold (2). Remove the fuel manifold from inlet manifold (9)
If necessary, remove fuel pressure sensor (3). Refer to Disassembly and Assembly, "Fuel Pressure Sensor - Remove and Install" for the correct procedure.
If necessary, remove fuel pressure relief valve (6). Refer to Disassembly and Assembly, "Relief Valve (Fuel) - Remove and Install" for the correct procedure. Installation Procedure
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.
Ensure that all ports on the fuel manifold are capped. Ensure that the fuel manifold is externally clean and free from damage. Note: Do not install a fuel manifold that has not been capped. All caps must be left in place until the fuel injection lines or the fuel pressure relief valve are installed.
Illustration 2 g03584583
If necessary, install fuel pressure sensor (3). Refer to Disassembly and Assembly, "Fuel Pressure Sensor - Remove and Install" for the correct procedure.
If necessary, install fuel pressure relief valve (6). Refer to Disassembly and Assembly, "Relief Valve (Fuel) - Remove and Install" for the correct procedure.
Position fuel manifold (2) onto inlet manifold (8). Install bolts (7) to fuel manifold (2) finger tight.
Install a new set of seals and a new set of fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure.
Tighten bolts (7) to a torque of 22 N m (195 lb in).
Connect harness assembly (4) to fuel pressure sensor (3).
Install a new sealing washer (6) (not shown) on to banjo bolt (1).
Remove the cap from tube assembly (5).
Install banjo bolt (1) to tube assembly (5). Install remaining new sealing washer (6) (not shown) to the banjo bolt.
Install banjo bolt (1) and tube assembly (5) to fuel manifold (2). Tighten the banjo bolt finger tight.
Tighten banjo bolt (1) to a torque of 21 N m (186 lb in). Ensure that tube assembly (5) is not strand as the banjo bolt is tightened.
Replace the filters for primary fuel system. Refer to Operation and Maintenance Manual, "Fuel System Primary (Water Separator) Element - Replace" for the correct procedure.
Replace the filters for secondary fuel system. Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure.
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for more information.