5001140 JOHNSON ENGINE COVER ASSY. - Z

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately.
Replace the secondary fuel filter elements whenever the following conditions occur:
The fuel filter differential pressure gauge registers 103 kPa (15 psi).
The fuel filters have been used for 1000 service hours.Replacing the Fuel Filter Elements with the Engine Stopped
Canister
Stop the engine. Ensure that the engine will not start during this procedure.
Shut off the fuel supply valve to the engine.
Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.
Use a suitable container to catch any fuel that might spill. Clean up any spilled fuel immediately.
Illustration 1 g01411122
(1) Bolts
(2) Cover
(3) Plug
(4) Drain valve
(5) Drain
Connect a hose to drain (5). Place the other end of the hose into a suitable container in order to collect the fuel.
Open drain valve (4). Remove plug (3). Allow the fuel to drain. Clean the plug and install the plug. Close the drain valve. Remove the hose from the drain. Note: Some fuel will remain in the housing after the fuel has been drained. This fuel will pour out of the housing when cover (2) is removed. Prepare to catch the fuel in a suitable container. Clean up any spilled fuel with absorbent towels or pillows. DO NOT use absorbent particles to clean up the fuel.
Personal injury can result from parts and/or covers under spring pressure.Spring force will be released when covers are removed.Be prepared to hold spring loaded covers as the bolts are loosened.
Be alert to the spring force. Gradually loosen but do not remove bolts (1). Before removing bolts (1), pry cover (2) loose in order to relieve any spring pressure. Remove cover (2). Remove the O-ring seal on the inside of the cover. Remove the fuel filter elements.
Clean cover (2) and clean the O-ring seal. Clean the inside of the fuel filter housing.
Install new fuel filter elements.
Inspect the O-ring seal. Ensure that the surfaces for the O-ring seal are clean. Install a new O-ring seal if the old O-ring seal is damaged or deteriorated.
Install cover (2). Ensure that the springs are seated properly between the cover and the fuel filter elements.
Open the fuel supply valve. Reconnect the battery.
Prime the fuel system. Refer to this Operation and Maintenance Manual, "Fuel System - Prime" topic (Maintenance Section). Spin-On Filter
Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component.
Illustration 2 g00425598
Secondary fuel filters
Remove the used fuel filter with a 1U-8760 Chain Wrench. Discard the used fuel filter.
Clean the gasket sealing surface of the fuel filter base. Ensure that all of the old gasket is removed.
Apply clean diesel fuel to the new fuel filter gasket.
Do not fill the fuel filters with fuel before installing the fuel filters. The fuel will not be filtered and could be contaminated. Contaminated fuel will cause accelerated wear to fuel system parts.
Install the new fuel filter. Spin the new fuel filter onto the fuel filter base until the gasket contacts the base. Tighten the fuel filter by hand by one full turn. Do not overtighten the fuel filter. Use the rotation index marks that are on the fuel filter as a guide for proper tightening.
Prime the fuel system. See this Operation and Maintenance Manual, "Fuel System - Prime" topic (Maintenance Section).Replacing the Fuel Filter Elements During Engine Operation
If the engine is equipped with duplex fuel filters, the fuel filters can be changed while the engine is in operation.
If the filter is changed during rapid air movement, an explosive vapor may be created. The explosive vapor may result in personal injury or in death.If rapid air movement exists, stop the engine in order to change the filter.
Filter contains hot pressurized fluid when engine is running.Follow instructions on control valve to avoid personal injury.
Duplex Fuel Filters
Illustrat