5000334 JOHNSON FUEL PUMP, High pressure

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Loctite C5A Copper Anti-Seize -
B 195-4609 Seal Pick 1
C - Isopropyl Alcohol -
D 5P-4996 Plug 2
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.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.
Turn the fuel supply to the OFF position and turn the power disconnect switch to the OFF.
Illustration 1 g03346521
Disconnect clamp assembly (1).
Remove three bolts (3).
Remove bolt (4). Remove tube assembly (2) and the gasket.
Illustration 2 g03346529Note: Cap all tube assemblies and fittings that are disconnected to prevent fluid loss. This action will also keep contaminants out of the systems.
Disconnect tube assemblies (5), (6), and (7). Plug tube assemblies (7) with Tooling (D). Remove bolt (8).
Illustration 3 g03346544
Disconnect ignition wire assembly (9) and cable assembly (11).
Remove allen bolt (10), the clamp assembly, and position wire assembly (12) out of the way.
Disconnect flame detection temperature sensor (13).
Illustration 4 g03346563
Remove nuts (18) and remove combustion head (17).
Remove gasket (16), tube assembly (15), and gasket (14).Note: The gaskets are for one time use only. Replace with new gaskets upon installation.
If required, remove studs (19).
Illustration 5 g03346567
Remove fittings (20) and (22).
Remove spark plug (21).
Illustration 6 g03346591
Use Tooling (B) to remove O-ring seals (23) and (24) from cable assembly (12). Discard the O-ring seals.Installation Procedure
Install combustion head (17) in the reverse order of removal.
Apply Tooling (A) onto the threads of studs (19). Install the studs. Tighten studs (19) to a torque of 17 2 N m (150 18 lb in).
Apply Tooling (A) onto the threads of the studs and nuts (18). Tighten nuts (18) in a crisscross pattern to a torque of 23 3 N m (204 27 lb in). Tighten nuts (18) again in a crisscross pattern to a torque of 28 3 N m (248 27 lb in). Tighten nuts (18) again in a crisscross pattern to a torque of 28 3 N m (248 27 lb in).
Use caution when you are using isopropyl alcohol. Avoid prolonged skin contact with isopropyl alcohol.Vapors may be harmful if inhaled. Use only in a well ventilated area. Do not smoke while using isopropyl alcohol.Isopropyl alcohol is flammable. Do not use near an open flame or near welding operations. Keep isopropyl alcohol away from heated surfaces exceeding 482°C (900°F).
Note: This connection is an electrical connection and cannot be lubricated with a petroleum-based lubricant. Isopropyl alcohol is the only approved lubrication for this connection.
Lubricate new O-ring seals (23) and (24) with Tooling (C) prior to installation.
Tighten fitting (22) to a torque of 60 6 N m (44 4 lb ft).
Tighten fittings (20) to a torque of 30 2 N m (266 18 lb in).
Tighten spark plug (21) to a torque of 57.5 4 N m (42 3 lb ft).
Apply Tooling (A) to the threads of flame detection temperature sensor (13) and install the sensor. Tighten flame detection temperature sensor (13) to a torque of 45 5