0211604 JOHNSON OWNERS MANUAL, Ev.

Table 1
Required Tools
Tool Part Number Part Description Qty
A 370-8376 Capping Kit 1
B 576–0970 Pentagonal Socket 1
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 g06399882
Typical example
Thoroughly clean the area around fuel manifold (4) and fuel pressure relief valve (3).
Illustration 2 g06399862
Disconnect harness assembly (5) from inlet manifold temperature sensor (6), and harness assembly (8) from inlet manifold pressure sensor (7), and harness assembly (7) from relief valve (3).
Follow Step 3a through Step 3e to remove the fuel pressure relief valve from the fuel manifold.
Ensure that the area around the fuel pressure relief valve (3) and fuel manifold (4) is still thoroughly clean.
Use a Tooling (B) to remove the fuel pressure relief valve retaining nut (1) from the body (2).
Remove the solenoid (3) from the body (2).
Remove the body (2) from fuel manifold (4).
Immediately cap the open port in fuel manifold (4) with Tooling (A). Immediately plug and cap the fuel pressure relief valve (3) with Tooling (A).Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
C - P-80 Emulsion Rubber Assembly Lubricant 1
D 8T-3052 Degree Wheel 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.
Illustration 3 g06399882
Typical example
Follow Step 1a through Step 1h to install the fuel pressure relief valve to the fuel manifold.
Remove the cap from the port in fuel manifold (4).
Immediately clean the threads in fuel manifold (4) for fuel pressure relief valve (3). Ensure that the thread is clean and free from debris. Ensure that the thread in the fuel manifold (4) is free from damage.
Immediately cap the open port in fuel manifold (4) with Tooling (A) after cleaning and inspection.
Apply tooling (C) to the O ring seal (2A) (not shown) of body (2). Install body (2) to fuel manifold (4).
Tighten body to a snug torque of 20 N m (177 lb in). Using Tooling (D), Rotate the fuel pressure relief valve in a clockwise direction for an additional 45 degrees to achieve the final torque.
Remove the cap from fuel pressure relief valve (3). Install fuel pressure relief valve (3) onto body (2).Note: DO NOT use the connector to stop solenoid turning.
Install nut (1) onto body (2), tighten nut to a snug torque of 5 N m (44 lb in). Using Tooling (C), and rotate the fuel pressure relief valve in a clockwise direction for an additional 13 degrees to achieve the final torque.
Remove the cap from fuel pressure relief valve (3) for the harness assembly. Connect the harness assembly (7) to fuel pressure relief valve (3).
Illustration 4 g06399862
Reconnect the harness assembly (5) to inlet manifold temperature sensor (6), and harness assembly (8) to the inlet manifold pressure sensor (7).
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.