0787029 JOHNSON Service Manual

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.
Turn the fuel supply to the OFF position.
Turn the battery disconnect switch to the OFF position.
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Slide locking tab (1) into the unlocked position. Disconnect harness assembly (2) from the coolant temperature sensor.
Cut cable strap (3).
Disconnect harness assembly (5) from fuel pressure sensor (6).
Disconnect assembly (9) from flow control valve (8).
Remove bolt (4) and bolt (10) (not shown) from bracket (7).
Position bracket (7) and the harness assembly away from the fuel injection pump.
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Clean the area around flow control valve (8) and fuel injection pump. Ensure that the area is free from contamination before beginning disassembly.
Make temporary marks on flow control valve (8) and the fuel injection pump for installation purpose.
Remove allen heads screws (11) from flow control valve (8).
Remove flow control valve (8) from the fuel injection pump. Remove O-ring seal (12). Installation Procedure
Ensure that all component at free from wear and damage. If any part of the flow control valve is worn or damaged, the flow control valve must be replaced as an assembly. The flow control valve kit contains the guide pins in order to install the flow control valve assembly.
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Flow control valve guide pins
Position a new O-ring seal (12) onto the fuel injection pump. Note: Ensure that the O-ring seal is correctly seated into the recess of the fuel injection pump.
Check O-ring seal (13) is correctly positioned. Ensure that O-ring seal (13) is not damaged. Note: If the O-ring seal is damaged, a new flow control valve assembly must be installed.
Install guide pins into Position (X) on the fuel injection pump. Note: Note the guide pins are part of the flow control valve repair kit.
Lubricate O-ring seal (13) with clean fuel. Note: Ensure that the O-ring seals are not damaged or misaligned.
Position flow control valve (8) onto guide pins. Note: Ensure that the flow control valve is correctly orientated
Install flow control valve (8) to the fuel injection pump.
Remove guide pins from the fuel injection pump.
Install allen head screws (11).
Tighten allen head screws (11) equally until the flow control valve is seated correctly onto the fuel injection pump. Note: Ensure that the allen head screws are tightened equally. Failure to ensure that the allen head screws are tightened equally will result in damage to the fuel injection pump.
Tighten the allen head screws to a torque of 9 N m (80 lb in).
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Position bracket (7) and harness assembly onto fuel injection pump.
Install bolt (4) and bolt (10) (not shown) to bracket (7). Tighten the bolts to a torque of 9 N m (80 lb in).
Connect harness assembly (5) to fuel pressure sensor (6).
Connect harness assembly (9) to flow control valve (8).
Connect harness assembly (2) to the coolant temperature sensor. Slide locking tab (1) into the locked position.
Install a new cable strap (3). Note: Ensure that the cable strap meets the Original Equipment Manufactures (OEM) specification.
Replace the filters for primary fuel system. Refer to Operation and Maintenance Manual, "Fuel System Primary (Water Separator) Element - Replace" for the correct procedure.
Replace the filters for secondary fuel system. Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure.
Turn the fuel supply to the ON position.
Turn the battery disconnect switch to the ON position.
Install the crankcase breather. Refer to Disassemble and Assemble, "Crankcase Breather - Install" for the correct procedure.
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for more information.
After replacement of the flow control valve, the fuel injection pump must be calibrated. Use the electronic service tool to perform "High Pressure Fuel Pump Calibration".