5034990 JOHNSON HOSE, FUEL (High Pressure)

Table 1
Required Tools
Tool Part Number Part Description Qty
B 268-1968 Injector Pipe Nut Tool 1
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.
This installation procedure is for installing one fuel injection line between the fuel manifold and the electronic unit injector.
Illustration 1 g03444839
Remove the cap from electronic unit injector (3) (not shown).
Install a new seal (2) to the cylinder head. Ensure that the flange on the seal is flush with the cylinder head.
Remove the cap from fuel manifold (5).
Install a new fuel injection line (1) to fuel manifold (5) and electronic unit injectors (3) (not shown) hand tight. Ensure that the ends of the fuel injection line are correctly seated in the electronic unit injector and in the fuel manifold.
Install the isolator and clamp (4) onto the fuel injection lines.Note: Ensure that the isolators are correctly positioned onto the fuel injection lines.
Use Tooling (B) to tighten the nuts on fuel injection line (1) to a torque of 30 N m (266 lb in).Note: Ensure that fuel injection lines do not contact any other engine component.
Install the crankcase breather canister and tube assemblies. Refer to Disassembly and Assembly, "Crankcase Breather - Install" for the correct procedure.
Turn the fuel supply to the ON position.
Turn the battery disconnect switch to the ON position.Installation Procedure for Set of Fuel Injection Lines
Table 2
Required Tools
Tool Part Number Part Description Qty
B 268-1968 Injector Pipe Nut Tool 1
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.
Ensure that wiring harness are correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness convoluting.
This installation procedure is for installing all fuel injection line between the fuel manifold, the electronic unit injectors, and the fuel injection pump. Loosening of all the electronic unit injectors and the fuel manifold will be necessary. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove" and Disassembly and Assembly, "Fuel Manifold (Rail) - Remove and Install" and for correct procedure.
Illustration 2 g03444858
Install new seals (7) to the electronic unit injector and the cylinder head. Ensure that the flange on the seals is flush with the cylinder head.
Remove the caps from new fuel injection line (1) and new fuel injection line (2).
Remove the caps from the appropriate ports fuel manifold (15) and fuel injection pump (8).
Position fuel injection line (1) and fuel injection line (2) onto fuel injection pump (8) and fuel manifold (15). Hand tighten the nuts for the fuel injection line onto the fuel manifold and the fuel injection pump.
Ensure that the ends of fuel injection line (1) and fuel injection line (2) are correctly seated in the fuel manifold and the fuel injection pump.
Position the clamps and isolator (9) and the clamps and isolator (12) to the fuel injection lines. Install new bolt (10) (not shown) and new bolt (11) hand tight. Ensure that the isolators are correctly positioned onto the fuel injection lines.Note: On some engines there may be only one clamp retaining the fuel injection lines to the cylinder head.
Position the clamps and isolator (14) to the fuel injection lines. Install the nut and bolt (13) hand tight.Note: Ensure that the isolators are correctly positioned onto the fuel injection lines.
Remove the caps from new fuel injection lines (3) and new fuel injection lines (5).
Remove the caps from the port of the electronic unit injector and from the ports in fuel manifold (16).
Loosely connect the nuts at both ends of fuel injection line (3) and fuel injection lines (5) to the electronic unit injector and to the appropriate port in fuel manifold (15). Ensure that the ends of the fuel injection line are correctly seated in the electronic unit injector and in the fuel manifold.
Install plastic clamp (4) and plastic clamp (6) to the assembly of fuel injection pipe (3) and the assembly of fuel injection pipe (5). Ensure that the plastic clamps are correctly seated onto the fuel injection lines.
Tighten the electronic unit injector and the fuel manifold. Refer to Disassembly and Assembly, "Electronic Unit Injector - Install" and Disassembly and Assembly, "Fuel Manifold (Rail) - Remove and Install" for the correct procedure.
Use Tooling (B) to tighten the nuts on fuel injection line (1) and fuel injection line (2) to a torque of 30 N m (266 lb in).Note: Ensure that fuel injection lines do not contact any other engine component.
Use Tooling (B) to tighten the nuts on the assembly fuel injection line (3) and the assembly fuel injection line (5) to a torque of 30 N m (266 lb in).Note: Ensure that fuel injection lines do not contact any other engine component.
Tighten the nuts and bolt (13) to a torque of 4 N m (35 lb in).
Tighten bolt (10) (not shown) and bolt (11) to a torque of 4 N m (35 lb in).
Install the crankcase breather canister and tube assemblies. Refer to Disassembly and Assembly