5036752 JOHNSON COVER ASSY, T STAT

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
B     -     Scotch Brite     1    
C     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    
D     9U-5470     Reamer     1    
E     4C-6161     Tube Brush     1    
F     9U-6862     Tapered Brush     1    
G     4C-6774     Vacuum Gun Kit     1    
H     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 (C) to remove the fuel and oil from the cylinder.Note: Tooling (F) 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 (B) is preferred. Clean the carbon from the cylinder head. If the sleeve of the unit injector has been removed from the engine, use Tooling (D) to remove only carbon from the surface of the sleeve. If the sleeve of the unit injector is installed in the engine, use Tooling (E) to clean the carbon deposit from the inside of the sleeve.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 (F) . Twist Tooling (F) with Tooling (H) 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 (G) 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.
Illustration 1 g01264405
Note: Check the O-ring seals for wear or for damage. If necessary, replace the O-ring seals.
Install O-ring seal (7) and O-ring seal (8) on unit injector (4) . Lubricate O-ring seal (7) , O-ring seal (8) , and the sleeve bore of the unit injector sparingly with clean engine oil.
Record the serial number for the injector and the confirmation code for the injector. When you install a new unit injector, the E-Trim value must be programmed into the Engine Control Module. For more information, refer to Troubleshooting, "Injector Code - Calibrate".
Illustration 2 g01264602
Place unit injector (4) into the bore. Make sure that key (9) for the unit injector fits into slot (10) in the cylinder head.
Illustration 3 g01264608
Do not reuse the injector hold down bolts. New injector hold down bolts must be used.
Note: Use new socket head bolt (3) for installation.
Position fuel injector clamp (6) with the label "C7" in the up position. Install socket head bolt (3) into fuel injector clamp (6) . Tighten socket head bolt (3) . Connect harness assembly (5) .
Illustration 4 g01457116
Inspect the sealing surface (A) for damage. Replace tube (1) if damage was found.
Illustration 5 g01264293
Illustration 6 g01340357
Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal.
Lubricate O-ring seal (2) with clean engine oil.
Install O-ring seal (2) onto tube (1) . Lubricate the nut face and the threads with clean engine oil. Insert tube (1) into the bore with the ball on the right side. The tube should drop slightly when the ball is engaged wi