0211603 JOHNSON OWNERS MANUAL Ev.

Table 1
Required Tools
Tool Part Number Part Description Qty
A 370-8376 Capping Kit 1 Start By:
Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove" 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 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.
Illustration 1 g06185357
Thoroughly clean the area around fuel manifold (7).
Disconnect harness assembly (2) from the electronic unit injector connection.
Disconnect the harness assembly from fuel pressure sensor (1).Note: The fuel pressure sensor is not serviceable. If the fuel pressure sensor is faulty, the fuel manifold assembly must be replaced.
Disconnect the harness assembly from electronic pressure limiting valve (3).Note: The electronic pressure limiting valve is not serviceable. If the electronic pressure limiting valve is faulty, the fuel manifold assembly must be replaced.
Remove banjo bolt (5) from plastic tube assembly connection (4). Use Tooling (A) to plug the plastic tube assembly Remove sealing washers (6) (not shown). Use Tooling (A) to plug fuel manifold (7).
Remove bolts (9) and position bracket (8) away from fuel manifold (7).
Remove fuel manifold (7) from the cylinder head.Installation Procedure
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 all ports on the fuel manifold are capped. Ensure that the fuel manifold is externally clean and free from damage.Note: Do not install a fuel manifold that has not been capped. All caps must be left in place until the fuel injection lines are installed.
Illustration 2 g06185357
Install bolt (9) to bracket (8).
Position fuel manifold (1) onto the cylinder head. Install bolts (9) to fuel manifold (7) finger tight.
Install a new set of seals to the electronic unit injectors and a new set of fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure.
Tighten bolts (9) to a torque of 44 N m (33 lb ft).Ensure that bracket (8) is positioned correctly.
Install a new sealing washer (6) (not shown) to banjo bolt (5).
Remove plug from plastic tube assembly (4). Install assembly of banjo bolt (5) to plastic tube assembly connection (4). Install remaining new sealing washer (6) (not shown) to banjo bolt (5).
Install banjo bolt (5) to fuel manifold (7) finger tight.
Tighten banjo bolt (5) to a torque of 18 N m (159 lb in).Note: Ensure that plastic tube assembly is not strained as banjo bolt is tightened.
Once banjo bolt (5) has been torqued. Wait 10 minutes and retighten banjo bolt (5) to a torque of 18 N m (159 lb in).Note: Ensure that plastic tube assembly is not strained as banjo bolt is tightened.
Connect the harness assembly to fuel pressure sensor (1).
Connect harness assembly (2) to the electronic unit injector connection.
Connect the harness assembly to electronic pressure limiting valve (3).
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.