0437506 JOHNSON COVER & PLUG AY, Water passage

1. Disconnect fuel injection nozzle (2) from adapter (1).2. Remove bolt (3), spacers and clamp that holds the fuel injection nozzle in place.
Never use force to remove the fuel injection nozzles. If necessary, turn and pull the fuel injection nozzle out of the cylinder head.
3. Pull adapter (1) out until fuel injection nozzle can be remove. Remove fuel injection nozzle (2).Install Fuel Injection Nozzles
Before the fuel injection nozzles are installed check for fuel leakage, the pressure at which the injection nozzle opens, and the amount of fuel (spray pattern) that comes out of the nozzle with tool (A). See TESTING FUEL INJECTION NOZZLES in TESTING AND ADJUSTING.
1. Remove carbon seal dam (2) with pliers. Remove compression seal (1). 2. Install a new compression seal on the nozzle. Install a new carbon seal dam with tool (B).3. Make sure the bore in the cylinder head and the fuel inlet fittings are clean. 4. Install fuel injection nozzle (2) in the head. Push and turn to install the nozzle into its correct position. 5. Put engine oil on the bore in the head for adapter (1). Push adapter (1) in position and connect fuel injection nozzle to the adapter. Tighten the nut to a torque of 30 5 lb.ft. (40 7 N m) with tool (C). While the nut is tightened, hold the adapter with a wrench 90° 2° with the centerline of the fuel injection nozzle.6. Install the spacers and clamp that hold the nozzle to the cylinder head.Disassemble Fuel Injection Nozzles
start by:a) remove fuel injection nozzles Do not disassemble any nozzle until a test has shown it is needed. Check each nozzle with tool (A) for leakage, the pressure at which the nozzle opens, and the shape and amount of fuel (spray pattern) that comes out of the nozzle. Do not clean or make an adjustment to any nozzle that has a large (excessive) amount of return leakage. Excessive return leakage can be an indication of nozzle failures that can not be corrected with an adjustment or cleaning and can cause engine damage. See TESTING 9L6969 FUEL INJECTION NOZZLES in TESTING AND ADJUSTING.
Keep the work area and all tools extra clean. Be careful not to cause damage to the parts while the nozzles are disassembled and assembled.
1. Remove cap (1) from the fuel injection nozzle. 2. Put the nozzle in tool (B). Put tool (B) and the nozzle in a vise. Do not put any part of a nozzle directly in a vise. Loosen locknut (2) while the lift adjustment screw is held. Turn the lift adjustment screw (3) counterlockwise one turn. Hold the lift adjustment screw (3) with a 5/64" hex wrench and remove the locknut (2).
If the lift adjustment screw is not turned counterclockwise one turn, the valve can be bent or the seat for the valve can be damaged when the pressure adjustment screw is turned.
3. Loosen the locknut (4) that holds the pressure adjustment screw. Use tool (D) to hold the pressure adjustment screw. 4. While the nozzle is held in one hand, tilt the nozzle and remove the pressure adjusting screw and locknut, spring, seat and valve. 5. If the valve does not slide out of the nozzle, install tool (C) and remove valve as follows: a) Push valve into nozzle with tool (C) until valve is against bottom of nozzle.b) Push down on body of tool (C) to engage collect on valve with tool (C).c) Turn nut counterclockwise and remove valve from the nozzle body. Put the parts in solvent to loosen carbon and deposits of foreign material. The body is assembled with an epoxy material and must not be in contact with the solvent for more than one to two hours. See SPECIAL INSTRUCTION FORM NO. SEHS7292 for the correct method to clean the nozzle.Assemble Fuel Injection Nozzles
Make sure all of the parts have been thoroughly cleaned before the nozzles are assembled. Flush the body to remove any debris or lapping compound.1. Put clean fuel on all of the parts. 2. Put valve (1) in position in the body as shown.3. Install lift adjustment screw (6) into pressure screw (5). Turn the lift adjustment screw two or three turns. Install the locknut (4) on the pressure adjustment screw (5).4. Put spring (3), and seat (2) in position on the adjustment screw (5).5. Put seat (2) in contact with the valve and push the valve into position in the body. Tighten the pressure screw by hand.6. Make an adjustment to the opening pressure of the nozzle as controlled by the pressure adjustment screw with tool (B). See TESTING 9L6969 FUEL INJECTION NOZZLES, OPENING PRESSURE TEST in TESTING AND ADJUSTING.7. Make an adjustment to the valve lift as controlled by the lift adjustment screw with tool (B). See TESTING 9L6969 FUEL INJECTION NOZZLES, VALVE LIFT ADJUSTMENT in TESTING AND ADJUSTING. 8. Put the nozzle in position on tool (A). Put tool (A) and the nozzle in a vise. Hold the lift adjustment screw (7) with a 5/64" hex wrench and tighten the locknut (8) until the adjustment screw will not turn. 9. Tighten the locknut for pressure adjustment screw to a torque of 70 to 80 lb.in. (8.0 to 9.1 N m).10. Tighten the locknut for the pressure adjustment screw to a torque of 35 to 45 lb.in. (4.0 to 5.1 N m). 11. Install the cap on the fuel injection nozzle. Use tool (C) to tighten the cap to a torque of 110 to 120 lb.in. (12.4 to 13.6 N m).end by:a) install fuel injection nozzle