0381804 JOHNSON CARBURETOR ASSEMBLY

Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Remove the valve cover and look for broken parts. Repair any broken parts or replace any broken parts that are found. Inspect all wiring for the solenoids. Look for loose connections. Also look for frayed wires or broken wires. Ensure that the connector for the unit injector solenoid is properly connected. Perform a pull test on each of the wires. Refer to Disassembly and Assembly Manual, "Electronic Unit Injector - Install".
Look for signs of fuel leakage. Investigate the source of the leaking fuel. Remedy the cause of the fuel leak.
Check the valve lash setting for the cylinder of the suspect unit injector. Refer to Testing and Adjusting, "Engine Valve Lash - Inspect/Adjust".
Remove the suspect unit injector. Refer to Disassembly and Assembly Manual, "Electronic Unit Injector - Remove". Check the unit injector for signs of exposure to coolant. Exposure to coolant will cause rust to form on the injector. If the unit injector shows signs of exposure to coolant, remove the injector sleeve and inspect the injector sleeve. Replace the injector sleeve if the injector sleeve is damaged. Check the unit injector for an excessive brown discoloration that extends beyond the injector tip. If excessive discoloration is found, check the quality of the fuel. Refer to Testing and Adjusting, "Fuel Quality - Test". Replace the seals on the injector and reinstall the injector. Refer to Disassembly and Assembly Manual, "Electronic Unit Injector - Install". Also refer to Disassembly and Assembly Manual, "Electronic Unit Injector Sleeve - Install". Inspect the injector for deposits of soot that are above the surface of the seat of the injector. Deposits of soot indicate combustion gas leakage. The source of the leak should be found, and the source of the leak should be remedied. The injector will not need to be replaced if combustion gas leakage was the problem.
If the problem is not resolved, replace the suspect injector with a new injector.Disconnecting and Connecting the Injector Harness
Use care when performing any engine service procedure that requires disconnecting the injector harness from the injectors. This helps to prevent future injector and/or injector harness connector failures
Note: Do not pull on the harness wires in order to remove the connector from the injector.Note: Do not apply excessive force to the connector body during removal.
When injector faults are present, carefully inspect the injector connector pins for arcing. Replace the suspect injector, and injector harness assembly when evidence of pin arcing is present.Note: Do not use socket connector repair kits at injector connections on engines utilizing this over-molded design. Wire length is critical in order to avoid contact with other components.
Ensure that the injector harness connector is fully engaged until the locking tab clicks into place.
Use 458-3562 Tool As to aid with disconnecting and connecting the injector harness connectors.
Note the location of the 458-3562 Tool As on the connector body when disconnecting and connecting the harness. The stop pin in the 458-3562 Tool As will prevent crushing the connector and reduce the chance for damage to wiring.
Illustration 1 g03715990
(2) 11mm Opening Minimum (3) 9.5mm Diameter Stop (4) Removal With 458-3562 Tool As (5) Installation With 458-3562 Tool As (6) 279 mm (11 inch) Pliers With 45 Degree Offset