0398693 JOHNSON POWERHEAD GASKET SET

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.
Table 1
Required Tools
Tool Part Number Part Description Qty
A 491-1265 Capping Kit 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.
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.If necessary, remove the breather hoses, refer to this Disassembly and Assembly, "Crankcase Breather - Remove and Install" for more information.
Illustration 1 g03816505
Illustration 2 g03816555
Illustration 3 g03816588
Remove clamp (9) and clamp (12).
Remove bolt (16) and nut (19A) from clamp assembly (9). Remove isolators (17) and (18). Remove bolt nut and isolators from clamp (12).
Disconnect nut (8) and nut (14). Remove fuel injection line (7). Install Tooling (A) to the fuel injector and the fuel manifold (20) when the fuel injection line is removed.
Disconnect nut (5) and nut (13). Remove fuel injection line (6). Install Tooling (A) to the fuel injector and the fuel manifold (20) when the fuel injection line is removed.
Disconnect nut (3) and nut (11). Remove fuel injection line (4). Install Tooling (A) to the fuel injector and the fuel manifold (20) when the fuel injection line is removed.
Disconnect nut (1) and nut (10). Remove fuel injection line (2). Install Tooling (A) to the fuel injector and the fuel manifold (20) when the fuel injection line is removed.Discard all fuel injection lines
Disconnect nut (19) and nut (23). Remove fuel injection line (22) from manifold (20) and pump (24). Install Tooling (A) to the fuel pump and fuel manifold (20) when the fuel injection line is removed. Discard the fuel injection line.
Illustration 4 g06594813
Typical Example
Loosen bolt (25) and bolt (26) by 1 turn from manifold (19).Fuel Injection Lines Install
All plugs and caps must remain in position until the component is about to be installed
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Position fuel injection line (22) onto fuel rail (20) and pump (24). Tighten nut (19) and nut (23) hand tight.
Illustration 6 g03816505
Position fuel injection line (2) onto fuel rail (20) and fuel injector. Loosely install fuel injection line. Position fuel injection line (4) onto fuel rail (20) and fuel injector. Loosely install fuel injection line.
Illustration 7 g03816555
Position isolator (18) and isolator (17) onto fuel injection lines (2) and (4). Install nut (19A) and bolt (16). Tighten nut and bolt to a torque of 3 N m (27 lb in).
Position fuel injection line (6) onto fuel rail (20) and fuel injector. Loosely install fuel injection line. Position fuel injection line (7) onto fuel rail (20) and fuel injector. Loosely install fuel injection line.
Align isolator (18