5034540 JOHNSON *SWITCH, EMERGENCY

Table 1
Required Tools
Tool Part Number Part Description Qty
A - LASER 4920
1/2 Inch Drive HP Fuel Line Socket Set 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.
Note: The following procedure should be adopted to install the fuel injection lines when the electronic unit injectors or the fuel manifold have not been removed. If the electronic unit injectors or the fuel manifold has been removed, refer to Disassembly and Assembly, "Electronic Unit Injector - Install" and Disassembly and Assembly, "Fuel Manifold - Install" for more information.
Illustration 1 g06326440
If the fuel manifold (1) has not been removed, ensure bolts (7) are torqued to 22 N m (195 lb in).
If the fuel manifold (1) has been removed, position fuel manifold (1) onto the cylinder head. Install bolts (7) to fuel manifold (1). Tighten bolts (7) finger tight.
Remove the relevant plugs from fuel manifold (1) and electronic unit injectors (5).
Remove the caps from new fuel injection line (6).
Position new fuel injection line (6) onto fuel manifold (1) and electronic unit injector (5). Install the nuts for the fuel injection line onto the fuel manifold and the electronic unit injector. Use Tooling (A) to tighten the nuts to a torque of 10 N m (89 lb in). Ensure that the fuel injection line is correctly seated onto the fuel manifold and the electronic unit injector.If fuel injection lines, do not seat correctly in the fuel manifold and the electronic unit injectors. The clamps for electronic unit injectors will need to be loosened. For electronic unit injectors that have been loosened the sealing washers and O-ring seal will need replacing. Refer to Disassembly and Assembly, Electronic Unit Injector - Remove and Electronic Unit Injector - Install for the correct procedure.
If necessary, repeat Step 3 through Step 5 to install remaining fuel injection lines (6).
Illustration 2 g06324288
Remove the plug from fuel manifold (1) and fuel injection pump (4).
Remove the caps from new fuel injection line (3).
Position new fuel injection line (3) onto fuel manifold (1) and fuel injection pump (4). Install nuts for the fuel injection line onto the fuel manifold and the fuel injection pump. Install new bolts (2) to the clamps. Hand tighten the bolts. Ensure that the fuel injection line is correctly seated onto the fuel manifold and the fuel injection pump.
Use Tooling (A) to tighten the nuts to a torque of 10 N m (89 lb in).
Illustration 3 g06143601
High-pressure fuel line tightening sequence
Tighten bolts (7) in Position (Y) and Position (Z) for fuel manifold (1) to a torque of 22 N m (195 lb in) as shown in Illustration 3. Ensure that the fuel injection lines (6) and fuel injection line (3) are not strained as the bolts are tightened.
Use Tooling (A) to tighten the nuts for fuel injection lines (6) by an additional 60 degrees in the sequence shown in Illustration 3.
Use Tooling (A) to tighten the nuts for fuel injection line (3) by an additional 60 degrees in the sequence shown in Illustration 3.
Tighten bolts (2) to a torque of 10 N m (89 lb in). Ensure that injection line (3) is not strained as the bolts are tightened.
Install Throttle valve (Intake Air), refer to Disassembly and Assembly, "Throttle valve (Intake Air) - Remove and Install".
Install Exhaust cooler (NRS), refer to Disassembly and Assembly, "Exhaust cooler (NRS) - Remove and Install".
If necessary, install the Clean Emissions Module (CEM). Refer to Disassembly and Assembly, "Clean Emissions Module - Remove and Install" 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 the correct procedure.