0312009 JOHNSON BRACKET,Starboard

Table 1
Required Tools
Tool Part Number Part Description Qty
B 339-9352 Injector System Cap Kit 1
265-2256 Wipers 1
C 312-3204 Brush 1
D - Scotch Brite 1
E 1U-5718 Vacuum Pump 1
169-7372 Fluid Sampling Bottle 1
4C-4057 Tube 1
4C-4055 Tube 1
F 9U-6862 Tapered Brush 1
G 4C-5027 Tap Wrench 1 Note: When Tooling (B) is removed, be careful to prevent contamination.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Use Tooling (E) to remove all fluid from the cylinder.
Use Tooling (D) to remove any carbon deposits from the unit injector tip.
Use a 38 mm (1.5 inch) square piece of Tooling (D) on the end of Tooling (F) and twist Tooling (F) with Tooling (G) to clean the injector bore.
Illustration 1 g06230734
When an electronic unit injector is replaced, the new electronic injector code must be programmed into the engine's personality module software by using the calibration menu on the Electronic Service Tool. If the new electronic injector code is not entered, the characteristics of the previous electronic unit injector is assumed.If it is not possible to immediately reprogram the electronic injector code into the personality module software, the engine will not be severely harmed. The new electronic injector code should be reprogrammed as quickly as possible in order to optimize engine performance.
When you install a new injector, the E-Trim value must be programmed into the engine control module. The injector confirmation code may need to be programmed into the engine control module. E-Trim Value (X) is a twelve-digit alphanumeric code that is supplied with the data sheet that comes with the new injectors. Injector Confirmation Code (Y) is a four-digit numeric code. Both of the codes are on the top of electronic unit injector (14). Refer to Troubleshooting , Injector Trim File- Install to program the E-Trim value.
Illustration 2 g01410032
If necessary, install new O-ring seals (10) and (11) onto electronic unit injector (8). Apply clean engine oil to O-ring seals (10) and (11).
Illustration 3 g02087670
Illustration 4 g03372119
Illustration 5 g03372132
Apply clean engine oil.
Check the cleanliness of the sealing surface for the unit injector in the cylinder head. If necessary, use Tooling (C) to clean the sealing cone on the unit injector.
Install electronic unit injector (8). Tighten bolt (9) to a torque of 30 - 50 N m (22 - 38 lb ft).
Loosen bolt (9).
Replace external O-ring seals on quill tube assembly (5). Apply clean engine oil to Area (X). Install quill tube assembly (5).Note: Do not allow the quill tube assembly (5) to contact any part of the engine while assembling.
Install new bolts (4) and (6) hand-tight.
Tighten bolt (9) to a torque of 10 N m (89 lb in).
Evenly tighten bolts (4) to a torque of 20 N m (177 lb in) in increments no greater than 90 degrees. Evenly tighten bolts (6) to a torque of 20 N m (177 lb in) in increments no greater than 90 degrees.
Tighten injector bolt (9) to a torque of 100 20 N m (74 15 lb ft).
Evenly tighten bolts (4) to a torque of 40 5 N m (30 4 lb ft) in increments no greater than 45 degrees. Evenly tighten bolts (6) to a torque of 40 5 N m (30 4 lb ft) in increments no greater than 45 degrees.
Connect harness assembly (7) onto electronic unit injector (8).
Illustration 6 g02087086
Connect harness assembly (2). Replace the O-ring seals on both ends of tube assembly (1). Install tube assembly (1). Install the washer and bolt (3).
Perform “fuel rail leakage - check”. Refer to Testing and Adjusting, KENR5397, "Fuel Rail Leakage - Check".End By:
Install the valve cover. Refer to Disassem