910121-6616 Tohatsu BOLT

Table 1
Required Tools
Tool Part Number Part Description Qty
A 370-8376 Cap Kit 1 Start By:
Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove" for the correct procedure.
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.
Illustration 1 g02484242
Illustration 2 g02484286
Thoroughly clean the area around fuel manifold (1).
Disconnect harness assembly (4) from fuel pressure sensor (5).
Remove banjo bolt (3) from plastic tube assembly (2). Use Tooling (A) to plug the plastic tube assembly Remove sealing washers (7) (not shown). Use Tooling (A) to plug fuel manifold (1).
Remove bolts (6).
Remove fuel manifold (1) from the cylinder block.
If necessary, remove fuel pressure relief valve (8) from fuel manifold (1). Ref to Disassembly and Assembly, "Relief Valve (Fuel) - Remove and Install" for the correct procedure. Installation Procedure
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.
Ensure that all ports on the fuel manifold are capped. Ensure that the fuel manifold is externally clean and free from damage. Note: Do not install a fuel manifold that has not been capped. All caps must be left in place until the fuel injection lines are installed.
Illustration 3 g02484242
Illustration 4 g02484286
If necessary, install fuel pressure relief valve (8) to fuel manifold (1). Ref to Disassembly and Assembly, "Relief Valve (Fuel) - Remove and Install" for the correct procedure.
Position fuel manifold (1) onto the cylinder block. Install bolts (6) to fuel manifold (1) finger tight.
Install a new set of seals to the electronic unit injectors and a new set of fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure.
Tighten bolts (6) to a torque of 22 N m (195 lb in).
Install a new sealing washer (7) (not shown) to banjo bolt (3).
Remove plug from plastic tube assembly (2). Install assembly of banjo bolt (3) to plastic tube assembly (2). Install remaining new sealing washer (7) (not shown) to banjo bolt (3).
Install banjo bolt (3) and plastic tube assembly (2) to pressure relief valve (8) finger tight.
Tighten banjo bolts (3) to a torque of 15 N m (133 lb in).
Connect harness assembly (4) to fuel pressure sensor (5).
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.