0385781 JOHNSON FUEL PUMP ASSY

Table 1
Required Tools
Tool Part Number Part Description Qty
A 370-8376 Cap Kit 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.
Remove the inlet air control (NRS Induction Mixer) and mounting bracket. Refer to Disassembly and Assembly, "Inlet Air Control (NRS Induction Mixer) - Remove" for the correct procedure.
Remove the crankcase breather cannister and tube assemblies. Refer to Disassembly and Assembly, "Crankcase Breather - Remove" for the correct procedure.
Illustration 1 g02177626
Cut cable straps (6) from the wiring harness assemblies.
Slide the locking tab for wiring harness connection (2) into the unlocked position. Remove wiring harness connection (2) from the pressure sensor.
Slide the locking tab for wiring harness connection (3) into the unlocked position. Remove wiring harness connection (3) from the pressure sensor.
Slide wiring harness connection (7) from the mounting bracket and position harness away from the inlet elbow.
Remove bolt (4) and bolt (8) from clips for tube assemblies.
Remove bolts (5) and remove manifold (1) from the inlet elbow.
Illustration 2 g02177627
Remove bolts (9) and remove inlet elbow (10) from the cylinder head.
Remove gasket (11).
Illustration 3 g02177628
Loosen bolt (22) and bolt (24) for tube clamp (13) support bracket.
Remove bolt (14) from tube clamp (13). Remove the tube clamp from fuel injection lines (12). Remove rubber separator (25).
Use a suitable tool in order to remove tube clamp (15) from fuel injection lines (12).
Loosen bolt (23) for tube clamp (17).
Remove bolt (18) from tube clamp (17). Remove tube clamp (17) from fuel injection lines (19). Remove rubber separator (26).
Clean the area around the nuts for fuel injection lines (12) and fuel injection lines (12). Ensure that the area is free from contamination before beginning disassembly.
Disconnect fuel injection line (12) from the electronic unit injector.
Disconnect fuel injection line (12) from fuel manifold (16).
Use Tooling (A) in order to plug the open port in the electronic unit injector immediately.
Remove fuel injection line (12). Discard the fuel injection lines.
Use Tooling (A) in order to plug the open port in fuel manifold (16) immediately.
Remove seal (20) from the electronic unit injector and cylinder head (21).
Repeat Step 19 through Step 25 in order to remove the remaining fuel injection lines from the fuel manifold to the electronic unit injectors.
Illustration 4 g02177629
Remove bolt (24) and bolt (25) from tube clip for fuel injection line (22).
Disconnect fuel injection line (22) from fuel injection pump (23).
Disconnect fuel injection line (22) at fuel manifold (16).
Remove fuel injection line (22). Discard the fuel injection lines.
Use Tooling (A) in order to plug all open ports immediately in fuel manifold (16) and in fuel injection pump (23).