5030512 JOHNSON COTTER PIN, Link

Table 1
Required Tools
Tool Part Number Part Description Qty
A 367-3070 Fuel Injector Installer As 1
D - Scotch Brite 1
E 149-2955 Seal Protector 1
F 149-2956 Seal Installer 1
G 1U-5718 Vacuum Pump 1
169-7372 Bottle Assembly 1
4C-4057 Clear Plastic Tubing
7.92 mm (0.312 inch) OD 1
4C-4055 Clear Plastic Tubing
6.35 mm (0.250 inch) OD 1
H 9U-5470 Reamer 1
J 4C-6161 Tube Brush 1
K 9U-6862 Tapered Brush 1
L 4C-6774 Vacuum Gun Kit 1
M 4C-5027 Tap Wrench 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Evacuate as much fuel and oil as possible from the cylinder head before installing the unit injector. Several evacuations may be necessary. Use Tooling (G) to remove the fuel and oil from the cylinder.Note: Tooling (L) is available to clean loose material from the sleeve bore and the cylinder.
Clean the carbon from the sleeve, the sleeve bore, and the end of the unit injector. Clean the carbon from the seat area that is inside of the cylinder head. A fine grade of Tooling (D) is preferred. Clean the carbon from the cylinder head and sleeves. If the sleeve of the unit injector has been removed from the engine, use Tooling (H) to remove the carbon. If the sleeve of the unit injector is installed in the engine, use Tooling (J) to remove the carbon.The following procedure is the preferred method of cleaning the sleeve bore.Place a 38 mm (1.5 inch) square piece of Scotch Brite material on the end of Tooling (K). Twist Tooling (K) with Tooling (M) against the lower surface of the sleeve bore.The surface should be cleaned until the surface is smooth and shiny. The entire sleeve bore should be cleaned in order to remove any loose carbon particles.Note: Tooling (L) is available to clean loose material from the sleeve bore and the cylinder.
The correct procedures and tooling specifications must always be used. Failure to follow any of the procedures may result in damage, malfunction, or possible engine failure.
The O-ring seals and the backup rings must be installed in the correct orientation. Damaged seals will result in excessive oil consumption or excessive leakage under the valve cover. Use care to prevent nicks or damage to the seals.
Illustration 1 g01123753
Lubricate O-ring seal (6), O-ring seal (7), O-ring seal (8), and the sleeve bore of the unit injector sparingly with clean engine oil.
Use Tooling (E) and Tooling (F) to install backup ring (4), backup ring (5), O-ring seal (6), backup ring (9), and O-ring seal (8).
Install O-ring seal (7).
Lubricate the O-ring seals and the backup rings on the unit injector with clean engine oil before installation.Note: Proper installation of the unit injector is important. Damage to the upper high-pressure seals can cause excessive oil leakage under the valve cover. The damage may cause the engine not to start due to a low actuation pressure. Damage to the lower high-pressure seals may allow high-pressure oil to leak into the fuel supply passage resulting in excessive oil consumption.Note: Do not hit or strike the unit injector during installation.
Record the serial number for the injector and the confirmation code for the injector. When a new unit injector is installed, the E-Trim value must be programmed into the Engine Control Module. For more information, refer to Troubleshooting, "Injector Code - Calibrate".
Illustration 2 g03028295
Illustration 3 g02608718
Use Tooling (A) to install unit injector (2) into the cylinder head.
Install socket head bolt (1b) on the exhaust side of the bracket. Tighten the exhaust side of socket head bolt (1b) until the bolt is seated.
Install socket head bolt (1a) on the inlet side of the bracket. Tighten the inlet side of socket head bolt (1a) to a torque of 16.5 1 N m (146 9 lb in).
Connect harness assembly (3).End By:
Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".