0215142 JOHNSON *DECAL, Front

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.
Engines with Bracket Installed
If the engine is equipped with a cover over the fuel system this will need to be removed.
Illustration 1 g01335251
The fuel manifold is shown with fuel injection lines in position.
If necessary, remove fuel pressure sensor (5). Refer to Disassembly and Assembly, "Fuel Pressure Sensor - Remove and Install".
If fuel pressure sensor (5) does not require removal, slide locking tab (4) into the unlocked position. Disconnect the plug on harness assembly (9) from fuel pressure sensor (5).
Disconnect tube assembly (7) from the fuel pressure relief valve on fuel manifold (3). Immediately cap the open port in fuel manifold (3) with a new cap. Immediately plug the open end of tube assembly (7) with a new plug.
Remove bolts (2) and spacer from fuel manifold (3). Note the position of the spacer for installation purposes.
Remove the bolt from fuel injection line clamp (6). Remove clamp assembly from the bracket.
Remove bracket (1) from fuel manifold (3).
Remove fuel manifold (3) from mounting bracket (8). Engines without Bracket Installed
If the engine is equipped with a cover over the fuel system this will need to be removed.
Illustration 2 g03326199
Typical example
If necessary, remove fuel pressure sensor (5). Refer to Disassembly and Assembly, "Fuel Pressure Sensor - Remove and Install".
If fuel pressure sensor (5) does not require removal, slide locking tab (4) into the unlocked position. Disconnect the plug on harness assembly (8) from fuel pressure sensor (5).
Disconnect tube assembly (6) from the fuel pressure relief valve on fuel manifold (3). Immediately cap the open port in fuel manifold (3) with a new cap. Immediately plug the open end of tube assembly (6) with a new plug.
Remove bolts (1) and spacer (2) from fuel manifold (3). Note the position of the spacer for installation purposes.
Remove fuel manifold (3) from mounting bracket (7). 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.
Engines with Bracket Installed
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 sensor are installed.
Illustration 3 g01335251
The fuel manifold is shown with fuel injection lines in position.
Position fuel manifold (3) on mounting bracket (8).
Install bracket (1) from fuel manifold (3).
Install bolts (2) to fuel manifold (3) finger tight.
Install the bolt to fuel injection line clamp (6). Tighten bolts (6) to a torque of 22 N m (16 lb ft). Ensure that fuel injection line does not contact any other engine component.
Install a new set of fuel injection lines and seals. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for more information.
Remove the plug from tube assembly (7). Remove the cap from the appropriate port in fuel manifold (3). Connect tube assembly (7) to the fuel pressure relief valve on fuel manifold (3). Tighten the connection to a torque of 30 N m (22 lb ft).
If fuel pressure sensor (5) was not removed from fuel manifold (3), connect the plug on harness assembly (9) to fuel pressure sensor (5). slide locking tab (4) into the locked position. If fuel pressure sensor (5) was removed from fuel manifold (3), install fuel pressure sensor (5) and a new sealing washer. Refer to Disassembly and Assembly, "Fuel Pressure Sensor - Remove and Install" for more information.
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for more information.
If the engine was equipped with a cover over the fuel system this will need to be installed. Engines without Bracket Installed
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 sensor are installed.
Illustration 4 g03326199
Typical example
Position fuel manifold (3) on mounting bracket (7).
Install spacer (2) to bolt. Install bolts (1) to fuel manifold (3) finger tight.