5030521 JOHNSON PLUG

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     370-8376     Cap Kit     1    
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct training.Before begining 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 Systems Operation, Testing and Adjusting Manual, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Turn the fuel supply to the OFF position.
Turn the battery disconnect switch to the OFF position.
Cleanliness is an important factor. Thoroughly clean the exterior of the component before commencing the disassembly procedure. Thoroughly cleaning the exterior of the component will help to prevent dirt from entering the internal mechanism.
Illustration 1 g02157019
Slide locking tab (3) into the unlocked position on connection for harness assembly (1) .
Disconnect harness assembly (1) from fuel pressure sensors (2) .
Slide locking tab on connection for harness assembly (4) into the unlocked position.
Disconnect harness assembly (4) for solenoid (5) .
Disconnect hose assembly (8) from the fuel control manifold. Use Tooling (A) in order to plug the hose assembly with a new plug. Use Tooling (A) in order to cap the connection with a new plug.
Remove O-ring seal (9) (not shown) from the connection on the fuel control manifold. Cap the open connection on the fuel control manifold with a new cap.
Disconnect hose assembly (7) from the fuel control manifold. Plug the hose assembly with new plugs.
Remove O-ring seal (6) (not shown) from the connection on the fuel control manifold. Cap the open connection on the fuel control manifold with a new cap.
Cut cable strap (10) and cable strap (11) for the harness assemblies.
Illustration 2 g02157394
Remove bolts (12) from fuel control manifold (14) .Note: Support the fuel control manifold on removal of the bolts.
Remove bracket (13) and bracket (15) .Note: Note position and orientation of bracket for installation purposes.
Remove fuel control manifold (14) from the bracket for the clean emission module.
Illustration 3 g02157021
If necessary, follow Step 16.a through Step 16.g in order to disassemble fuel control manifold (14) .
Use a deep socket in order to remove fuel pressure sensor (2) from fuel control manifold (14). Remove O-ring seal (20). Cap the fuel pressure sensor with a new cap. Plug the open port on the fuel control manifold with a new plug.
Remove nut (16) from the valve assembly and remove solenoid (5). Use a deep socket in order to remove valve assembly (17) from fuel control manifold (14). Plug the open port on the fuel control manifold with a new plug.
Remove O-ring seal (18) and O-ring seal (19). Cap the valve assembly with a new cap.
Remove connection (21) from fuel control manifold (14). Plug all open ports on the fuel control manifold with new plugs.
Remove O-ring seal (22) and cap connection (21) with new caps.
Remove connection (24) from fuel control manifold (14). Cap connection (24) with a new cap.
Remove O-ring seal (23) from fuel control manifold (14). Plug the open port on the fuel control manifold with a new plug.Installation Procedure
Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
Illustration 4 g02157021
If necessary, follow Step 2.a through Step 2.f in order to assemble fuel control manifold (14) .
Remove the cap from connection (21). Install a new O-ring seal (22) to connection (21). Remove the plug from the fuel control manifold. Install connection (21) to fuel control manifold (14). Tighten the connection to a torque of 43 N m (32 lb ft).
Remove plugs from fuel control manifold (14). Install new O-ring seal (23) to fuel control manifold (14) .
Remove the cap from connection (24). Install connection (24) to fuel control manifold (14). Tighten connection (24) to a torque of 43 N m (32 lb ft).
Remove the cap from valve assembly (17). Install new O-ring seals (18) and O-ring seals (19) to valve assembly (17). Remove plug from the fuel control manifold. Use a deep socket in order to install valve assembly (17) to fuel control manifold (14). Tighten the valve assembly to a torque of 50 N m (37 lb ft).
Install solenoid (5) to valve assembly (17). Install nut (16 ). Tighten the nut to a torque of 20 N m (177 lb in).
Remove the cap from fuel pressure sensor (2). Install a new O-ring seal (20) to fuel pressure sensor (2). Remove plugs from fuel control manifold (14). Use a deep socket to install the fuel pressure sensor to the fuel manifold. Tighten the fuel pressure sensor to a torque of 20 N m (177 lb in).