5006588 JOHNSON Service Manual - English

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     5P-0332     Crowfoot Wrench     1    Start By:
Remove the fuel pressure relief valve, if necessary. Refer to Disassembly and Assembly, "Relief Valve (Fuel) - Remove and Install".
Remove the fuel lines. Refer to Disassembly and Assembly, "Fuel Lines - Remove and Install".
Contact with high pressure fuel may cause personal injury or death. Wait 60 seconds after the engine has stopped to allow fuel pressure to purge before any service or repair is performed on the engine fuel lines.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
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.
Fuel injection lines MUST only be used once. Discard all fuel injection lines after use.
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.
Illustration 1 g01444461
Note: Plug all hose assemblies and all tube assemblies. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system.
Disconnect harness assembly (1) .Note: A new fuel rail includes the fuel pressure sensor, the adapter, and the fuel pressure relief valve.
Fuel pressure sensor (2) must only be used once. Discard fuel pressure sensor (2) after use.
Use Tooling (A) in order to remove fuel pressure sensor (2) , if necessary. Discard fuel pressure sensor (2) .
Remove adapter (3) , if necessary.
Remove tube assembly (4) from fuel rail (5) .
Remove bolts (6) and remove fuel rail (5) .Installation Procedure
Table 2
Required Tools    
Tool     Part Number     Part Description     Qty    
A     5P-0332     Crowfoot Wrench     1    
B     161-9203     Grease Cartridge     1    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Fuel injection lines MUST only be used once. Discard all fuel injection lines after use.
Illustration 2 g01444461
Position fuel rail (5) and install bolts (6) . Tighten bolts (6) to a torque of 28 7 N m (21 5 lb ft).
Install tube assembly (4) on fuel rail (5) . Install the fuel lines. Refer to Disassembly and Assembly, "Fuel Lines - Remove and Install".
Apply Tooling (B) to the threads and face of adapter (3) .Note: A new fuel rail includes the fuel pressure sensor, the adapter, and the fuel pressure relief valve.
Install adapter (3) , if necessary. Tighten adapter (3) to a torque of 95 3 N m (70 2 lb ft).
Use Tooling (A) in order to install new fuel pressure sensor (2) , if necessary. Tighten fuel pressure sensor (2) to a torque of 35 3 N m (26 2 lb ft).
Connect harness assembly (1) .End By: Install the fuel pressure relief valve, if necessary. Refer to Disassembly and Assembly, "Relief Valve (Fuel) - Remove and Install".