5032578 JOHNSON SHIM (T:1.2mm)

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.
Illustration 1 g06145778
Clean the area around flow control valve (1) and fuel injection pump (3). Ensure that the area is free from contamination before beginning disassembly.
Make temporary marks on flow control valve (1) and fuel injection pump (3) for installation purpose.
Disconnect harness assembly (2) from flow control valve (1).
Remove Allen heads screws (4) from flow control valve (1).
Remove flow control valve (1) from fuel injection pump (3). Remove O-ring seal (5) and O-ring seal (6).Installation Procedure
Ensure that all components, are 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 overhaul kit contains the guide pins to install the flow control valve assembly.
Illustration 2 g06145778
Illustration 3 g06146027
Flow control valve guide pins
Install guide pins into Position (X) on fuel injection pump (1).Note: The flow control valve overhaul kit contains the guide pins.
Position a new O-ring seal (6) to flow control valve (1). Ensure that the O-ring seal is correctly position in the recess of the flow control valve.
Position a new O-ring seal (5) to flow control valve (1). Ensure that the O-ring seal is correctly located onto the flange of the flow control valve.
Lubricate O-ring seal (6) with clean fuel.
Position flow control valve (1) onto guide pins.Note: Ensure that the flow control valve is correctly orientated
Install flow control valve (1) to fuel injection pump (3).
Remove a guide pin from fuel injection pump (3). Install Allen head bolt (4) finger tight. Remove the remaining guide pin and install the remaining Allen head bolt finger tight.
Equally tighten Allen head bolt (4) to a torque of 10 N m (89 lb in).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.
Connect harness assembly (2) to flow control valve (1).
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.
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".