0335658 JOHNSON O-RING, Fill plug

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High Pressure Fuel Pump (HPFP) on engine
(1) Side port plugs
Turn off the engine and remove the HPFP side port plugs (1). Inspection procedure is most effective if the engine has been turned off for minimum one hour. A small quantity of oil may drain from the HPFP. Retain the side port plugs (1) for reinstallation later.Note: O-rings may stick to pump housing, if so remove the O-ring and again install to the side port plug (1).
If a plug is dropped or lost, replacement plug can be ordered (Service parts (F)& (G)).
If an O-ring is damaged, a replacement O-ring can be ordered (Service parts (G)).
Illuminate the camshaft using a flash light and visually inspect the surface of the cam lobe in the first port (Closest to front of engine). Evaluate the cam lobe surface for surface texture and appearance. Example pictures of acceptable, monitor and failed cam lobes are show in "Cam Condition: Acceptable" Section, "Cam Condition: Monitor" Section, and "Cam Condition: Failure (HPFP Failed)" Section.
If the condition of the cam lobe is questionable, use the borescope (Tool(A)) to further evaluate the condition of the pump cam. If the condition does not clearly match one of the three conditions (Acceptable, Monitor or Failure), use the borescope to photograph the cam lobe in uncertain condition and attach them to a Dealer Solution Network (DSN) ticket.
Repeat the inspection for the remaining three cam ports.
If any cam lobes have a condition like "Failure" shown in "Cam Condition: Failure (HPFP Failed)" Section, the HPFP should be replaced. Refer to Disassembly and Assembly , Fuel Pump (High Pressure) - Remove and Install for more information.
If all four lobes are in acceptable condition, an additional inspection can be completed to increase confidence in health of the HPFP. Bar the engine one-third of a revolution and again inspect all four cam ports. It is possible for the HPFP cam to show damage on only one lobe and only part way around the cam lobe. This process will confirm the cam is acceptable on all sides of all lobes. If all four lobes are still acceptable, no additional action is needed. If any lobe shows signs of damage (Failure) after rotation, the HPFP should be replaced. Refer to Disassembly and Assembly , Fuel Pump (High Pressure) - Remove and Install for more information.
Again install the four side port plugs and torque to 27 N m (239 lb in).
Do not attempt to refill HPFP with oil. The HPFP will refill oil on the next engine crank/start.Cam Condition: Acceptable
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Typical example of acceptable cam condition
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Typical example of acceptable cam condition
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Typical example of acceptable cam condition
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Typical example of acceptable cam condition
Clearly visible cross-hatch polishing pattern.
Even surface texture across the cam lobe.
Minimal (1–2) lines or marks around cam lobes - camshaft will occasionally have tracking marks around the lobes, which is typical and does not necessarily indicate an issue.Action : Continue 500 hour visual camshaft inspections.Cam Condition: Monitor
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Typical example of cam condition to be monitored
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Typical example of cam condition to be monitored
Several minor lines or marks around cam face.
Cross-hatch polish still visible across cam face.
Lines may have some width and may not reflect light.Action : Continue 500 hour visual camshaft inspection, consult DSN with additional question or concerns on pump camshaft health.Cam Condition: Failure (HPFP Failed)
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Typical example of failed cam condition
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Typical example of failed cam condition
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Typical example of failed cam condition