0337207 JOHNSON COVER, Thermostat

1. Loosen clamps (2), (3) and (4) to remove tube assembly (1) and the hoses from the engine. 2. Loosen the clamps and remove hose (5) from the crankcase ventilator valve and air inlet manifold.3. Thoroughly clean the area around each fuel line connection before any fuel lines are removed.4. Put identification of the fuel injection lines as to their location on the fuel injection pumps and adapters. 5. Disconnect fuel injection lines (7) from the adapters and the fuel injection pump housing. Remove bolt (6) and remove fuel injection lines (7).
Put protection caps (5F2807) and plugs (2F2990) on the lines and pumps to keep dirt and foreign material out of the fuel system.
6. Disconnect fuel injection lines (8) from the fuel injection pump housing, adapters and the fuel filter and remove them from the engine. 7. Loosen bolt (11). Remove the five bolts (10) and one nut and remove air inlet manifold (9). 8. Disconnect return line (12) from the fuel injection pump housing and junction block to remove it from the engine.9. Put tape over the openings in the cylinder heads to keep dirt and foreign materials out of the engine.Install Fuel Injection Lines And Air Inlet Manifold
1. Remove the plugs and caps from the fuel lines. 2. Put return line (1) in position and connect it to the fuel injection pump housing and the junction block.3. Remove the tape from the openings in the cylinder heads. 4. Put air inlet manifold (3) and gaskets (2) in position on the engine and install the bolts and one nut that hold it in place. If the adapters in the air inlet manifold were removed, put 8H4137 Sealer on the threads of the adapters and tighten them to a torque of 9 3 lb.ft. (12 4 N m).5. Tighten the bolts (6) and (7) to a torque of 15 5 lb.ft. (20 7 N m) then tighten the bolts and one nut in number sequence shown to a torque of 32 5 lb.ft. (43 7 N m). Remove bolt (10) to install the fuel line bracket.6. Make sure the fuel injection lines are clean and dry. 7. Put fuel injection lines (12) in position on the engine and connect them to their respective fuel injection pumps, adapters and fuel filter base. 8. Put fuel injection lines (13) in position on the engine and connect them to their respective fuel injection pumps and adapters.9. Install the bolt through the bracket for fuel injection lines (13) that holds the air inlet manifold.10. Tighten the nuts for fuel injection lines (12) and (13) to a torque of 30 5 lb.ft. (40 7 N m). 11. Install hose (14) between the air inlet manifold and the crankcase ventilator valve. Tighten the clamps to a torque of 20 5 lb.in. (2.3 0.6 N m). 12. Put tube assembly (15) in position with the hoses and tighten the clamps to a torque of 18 5 lb.ft. (24 7 N m)13. Remove (bleed) the air from the fuel system.
If new fuel lines are used for replacement, remove the identification tags from the lines. The tags can cause wear on the fuel injection lines.