0435131 JOHNSON CARBURETOR ASSY.

Hot engine oil can cause personal injury if it contacts the skin. Use caution when draining the oil.
2. Engine Accessory Removal
(1) Removing turbocharger [turbocharged engines] (a) Disconnect pipe (1) between the turbocharge and inlet manifold.(b) Disconnect turbocharger lubricating oil pipe (2) and drain pipe (3).(c) Remove turbocharger (4) from the exhaust manifold.(2) Removing exhaust manifold Unscrew bolts securing exhaust manifold (1), and remove the manifold and gasket (2). (3) Removing thermostat (S4K, S4K-T) (a) Disconnect water bypass hose (1).(b) Remove thermostat case (2).(4) Removing water outlet pipe and thermostat (S6K, S6K-T) (a) Disconnect water bypass hose (1).(b) Remove water outlet pipe (2) and thermostat case (3) as an assembly.(5) Removing fuel filter (a) Disconnect fuel pipes (1)(2).(b) Remove fuel filter (3) and bracket (4) as an assembly.(6) Removing fuel injection pipes (a) Remove pipe clamp (1), and disconnect injection pipes (2).(b) Unscrew lock nut (3), and remove leak-off pipe (4).
Be sure to fit rubber caps to the openings of the injection pumps and nozzle holders to prevent dust from getting inside the fuel system.
(7) Removing fuel injection nozzles Take off nozzle gland (1), and remove injection nozzle (2) and gasket (3).(8) Removing inlet manifold and air heater Unscrew the bolts securing inlet manifold (1), and remove the manifold and gasket (2) complete with air heater (3).(9) Removing fuel injection pump (a) Disconnect oil pipe (1), and remove cover (2).(b) Unscrew bolts (3), and remove injection pump (4) complete with gear and mounting flange from the front plate.(10) Removing fan and water pump (a) Remove fan (1), and slacken and remove fan belt (2).(b) Unscrew the bolts securing water pump (3), and remove the pump and pulley (4) as an assembly.(11) Removing alternator (a) Disconnect harness (1), and unscrew bolt (2) securing the belt adjusting plate.(b) Unscrew bolts (3), and remove alternator (4).(12) Removing starter Disconnect harness (1). Unscrew bolts (2), and remove starter (3).(13) Removing oil filter Unscrew bolts (1), and remove oil filter (2) and filter bracket (3) with gasket (4).(14) Removing oil pan Unscrew bolts (1), and remove oil pan (2).(15) Removing oil cooler Unscrew bolts (1), and remove the oil cooler attached to cover (2). Remove gasket (3).(16) Removing air heater Unscrew the bolts securing air inlet elbow (1), and remove the elbow, air heater (2) and gasket (3)(4). Gasket (4) is to come to the manifold side when installed.3. Engine Accessory Installation
Matching marks on timing gearsTo install the accessories, follow the reverse of removal procedure, and take the following steps:(a) Installing fuel injection pump When installing the pump, make sure that matching marks on pump drive gear and other gears are aligned with those on idler gear respectively, as shown. With these matching marks are all aligned, No. 1 cylinder piston is at top dead center on compression stroke.(b) Refill the engine with recommended oil up to the specified level.(c) Refill the cooling system with coolant.(d) Check each pipe connection for oil or coolant leaks.(e) Prime the fuel system.(f) After installing the fuel injection pumps, inspect and adjust the injection timing. (Refer to 1.3, Group No. 5.)