5032897 JOHNSON GASKET, Inlet manifold

Table 1
Required Tools
Tool Part Number Part Description Qty
A 388-1289 Capping Kit 1 Start By:
Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove" for the correct procedure.
If necessary, remove the Exhaust Gas Recirculation (EGR) valve. Refer to Disassembly and Assembly, "Exhaust Gas Recirculation Valve - Remove and Install" 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 authorised personnel that have the correct training.Before begining 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 Systems Operation, Testing and Adjusting Manual, "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: Place identification marks on all hoses, on all hose assemblies, on wires and on all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. Plugging all hose assemblies and tube assemblies will prevent fluid loss. Plugging all hose assemblies and tube assemblies will to keep contaminants from entering the system.Note: Plug or cap all open ports with new plugs or caps.
Illustration 1 g03785138
Illustration 2 g03828989
Disconnect the wiring harness assembly from electronic unit injector (1). Note: Make a temporary mark on the wiring harness assembly in order to ensure that the wiring harness assembly is connected to the correct electronic unit injector during assembly.
Disconnect hose assembly (5) from electronic unit injector (1). Remove O-ring seal (6) from the hose assembly.
Use Tooling (A) in order to cap electronic unit injector (1) immediately. Use Tooling (A) in order to plug hose assembly (5) immediately.
Remove nut (2) and washer (7) from clamp (3). Note: Note the orientation of the washer.
Make a temporary mark on the electronic unit injector in order to ensure that the electronic unit injector is reinstalled in the original location.
Remove the electronic unit injector and clamp (3) from the cylinder head. Note: Always handle electronic unit injectors with care.
Remove clamp (3) from electronic unit injector (1).
If electronic unit injector (1) is to be reused, Follow Step 9 through Step 11 in order to remove sealing washer (8).
Use a suitable tool in order to remove sealing washer (8) from electronic unit injector (1). If sealing washer (8) is not present on the electronic unit injector, ensure that the sealing washer is removed from the cylinder head. Note: Ensure that the nozzle for the electronic unit injector is not damaged in any way during removal of the sealing washer.
Remove O-ring seal (9) from the electronic unit injector.
Install Tooling (A) to the nozzle for electronic unit injector (1) immediately.
If necessary, repeat Step 1 through Step 9 in order to remove the remaining electronic unit injectors. In some applications removal of the clean emissions bracket and exhaust gas recirculation valve will be necessary in order to remove number four electronic unit injector. Refer to Disassembly and Assembly, "Support and Mounting (CEM) - Remove and Install" and Disassembly and Assembly, "Exhaust Gas Recirculation Valve - Remove and Install" for the correct procedures.
If necessary, remove studs (4) from the cylinder head.