3GR-70020-0 Tohatsu FUEL TANK CAP ASSEMBLY

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 g02178677
Thoroughly clean the area around fuel manifold (4).
Disconnect harness assembly (6) from fuel pressure sensor (5).
Disconnect plastic tube assembly (1) from the fuel pressure relief valve on fuel manifold (4). Immediately cap the open port in fuel manifold (4) with a new cap. Immediately plug the open end of plastic tube assembly (1) with a new plug.
Remove bolt (2) and bolts (3). Remove fuel injection line support bracket (7).
Remove fuel manifold (4) from the cylinder head.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 or the fuel pressure relief valve are installed.
Illustration 2 g02178677
Position fuel manifold (4) onto the cylinder head. Install bolts (3) to fuel manifold (4) finger tight.
Position fuel injection line support bracket (7) onto the fuel rail. Install remaining bolt (3). Install bolt (2) for injection line support bracket (7) finger tight.
Install a new set of seals and a new set of fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure.
Tighten bolts (3) to a torque of 22 N m (195 lb in).
Tighten bolts (2) to a torque of 10 N m (89 lb in).
Remove the plug from plastic tube assembly (1). Connect plastic tube assembly (1) to the fuel pressure relief valve.
Connect harness assembly (6) to fuel pressure sensor (5).
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.
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for more information.End By:
Install the mounting bracket and the inlet air control (NRS Induction Mixer). Refer to Disassembly and Assembly, "Inlet Air Control (NRS Induction Mixer) - Install" for the correct procedure.