0381025 JOHNSON NEEDLE ROLLER SET ASSY.

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     276-1216     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.
Note: The following procedure should be adopted in order to install the fuel injection lines when the electronic unit injectors or the fuel manifold have not been removed. If the electronic unit injectors or the fuel manifold have been removed, refer to Disassembly and Assembly, "Electronic Unit Injector - Install" and Disassembly and Assembly, "Fuel Manifold - Install" for more information.
Illustration 1 g01335193
Typical example
Remove the cap from the port of electronic unit injector (1) . Install a new seal (5) to electronic unit injector (1) . Ensure that the electronic unit injector end of the seal is correctly aligned to the injector. Ensure that the flange on the seal is flush with the valve mechanism cover base. Do not use excessive force to insert the seal (5) as this may cause damage to the valve mechanism cover base and could prevent the formation of an effective seal.
Remove the cap from the appropriate port in fuel manifold (4) .
Connect the nuts at both ends of fuel injection line (2) , to electronic unit injector (1) and to the appropriate port in fuel manifold (4) . Hand tighten the nuts at both ends of fuel injection line (2) . Ensure that the ends of the fuel injection line are correctly seated in the electronic unit injector and in the fuel manifold.Note: If the fuel injection line cannot be correctly aligned, the process for removing and installing an electronic unit injector should be followed. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove" and Disassembly and Assembly, "Electronic Unit Injector - Install" for the correct procedure.
Repeat steps 1 through 3 in order to install the remaining fuel injection lines.
Illustration 2 g03093726
Typical example of later type clamp
Illustration 3 g03093916
Typical example
Install isolator (17) for clamp (14) to fuel injection line (2) .Note: Ensure that the isolator is correctly positioned and oriented onto fuel injection lines.
Position top section (16) onto isolator (17) and install bottom section (18) to top section (16) . Loosely install bolt (15) hand tight. Ensure that the locating Tag (A) faces the valve mechanism cover.Note: Ensure that fuel injection lines do not contact any other engine component.
Use a suitable tool in order to hold the clamps in Position (B) . Tighten bolt (15) for the clamp (14) to a torque of 9 N m (80 lb in). Ensure that is no visible gap between the top section (16) and the bottom section (18) of the clamp (14) .
If installing a new fuel manifold (rail), tighten the bolts that secure the fuel manifold (4) to the ECM bracket. Tighten the bolts to a torque of 22 N m (16 lb ft).Note: If new electronic unit injectors are installed, the torx screw for the electronic unit injector clamp should be tightened to the correct torque. Refer to Disassembly and Assembly, "Electronic Unit Injector - Install" for more information.
Use Tooling (A) to tighten the nuts at the electronic unit injector end on the new fuel injection lines (2) to a torque of 30 N m (22 lb ft). Ensure that the dust seal is seated correctly against seal (5) .
Use Tooling (A) to tighten the nuts at the fuel manifold end on the new fuel injection lines (2) to a torque of 30 N m (22 lb ft).
Illustration 4 g01335197
Assembly of the tube clip
Illustration 5 g01335195
Loosely install tube clips (12) and the allen head screws (13) to the fuel injection line (6) .
Remove the caps from the port in fuel injection pump (7) and from the appropriate port in fuel manifold (4) . Remove the caps from new fuel injection line (6) .
Place fuel injection line (6) in position.
Connect the nuts at both ends of fuel injection line (6) , to fuel manifold (4) , and to fuel injection pump (7) . Hand tighten the nuts at both ends of fuel injection line (6) . Ensure that the ends of the fuel injection line are correctly seated in the fuel injection pump and in the fuel manifold.
Install the bolts (11) finger tight for tube clips (12) that secure fuel injection line (6) .
Tighten bolts (11) to a torque of 22 N m (16 lb ft). Tighten allen head screws (13) to a torque of 10 N m (89 lb in). Ensure that fuel injection line does not contact any other engine component.
Use Tooling (A) to tighten the nuts at the fuel injection pump end of fuel injection line (6) to a torque of 30 N m (22 lb ft).
Use Tooling (A) to tighten the nuts at the fuel manifold end of fuel injection line (6) to a torque of 30 N m (22 lb ft).
Illustration 6 g01335194
Typical example