0439210 JOHNSON CRANKCASE HEAD ASSY.

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 9U-6198 Crankshaft Turning Tool 1
A(2) 5P-7306 Housing 1
5P-7305 Engine Turning Tool 1
B 136-4632 Timing Pin (Crankshaft) 1
268-1966 Adapter 1
C 364-9107 Timing Pin (Fuel Injection Pump) 1
D 370-8376 Plugging Kit 1
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.Start By:
Remove crankcase breather canister and plastic tube assemblies. Refer to Disassembly and Assembly, "Crankcase Breather - Remove" for the correct procedure. Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Turn the fuel supply to the OFF position.
Turn the battery disconnect switch to the OFF position.
Illustration 1 g02482036
Remove plug (11) and remove O-ring seal (10) (not shown).
Install Tooling (C) to fuel injection pump (13).
Use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead center. Refer to System Operation, Testing and Adjusting, "Fuel Injection Timing - Check" for the correct procedure.
Use Tooling (B) in order to ensure that the crankshaft is locked with number one piston at top dead center.
Cut cable strap (3) from harness assembly (1).
Disconnected harness assembly (1) from coolant temperature sensor (2). Refer to Disassembly and Assembly, "Coolant Temperature Sensor - Remove and Install" for the correct procedure.
Disconnected harness assembly (7) from the pressure sensor in the fuel manifold.
Disconnected harness assembly (16) from the flow control valve.
Disconnected harness assembly (14) from the fuel temperature sensor.
Disconnected harness assembly (15) from the engine oil pressure sensor. Refer to Disassembly and Assembly, "Engine Oil Pressure Sensor - Remove and Install" for the correct procedure.
Remove bolt (4) and bolt (9) (not shown) from bracket (5). Remove the bracket and position away from the fuel injection pump. Note: The harness assemblies should be positioned away from the fuel injection pump in order to avoid an obstruction during the removal of the fuel injection pump.
Clean fuel injection pump (13) and the area around the fuel injection pump. Ensure that the area is free from contamination before beginning disassembly.
Place a suitable container below fuel injection pump (13) in order to catch any fuel that might be spilled.
Disconnect plastic tube assembly (6) and plastic tube assembly (8) from fuel injection pump (13). Use Tooling (D) in order to plug the plastic tube assemblies. Cap the connections for plastic tube assemblies on the fuel injection pump.
Remove fuel injection line (12) that connects fuel injection pump (13) to the fuel manifold. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove" for the correct procedure.
Use Tooling (D) in order to plug the open ports in the fuel injection pump and in the fuel manifold. Discard the fuel injection line.
Illustration 2 g02482038
Remove nuts (19) and bolts (22) from fuel injection pump (13). Note position of the different length bolts. Note: The fuel injection pump should be supported by hand as the bolts are removed.
Carefully remove fuel injection pump (13) from front housing (20). Ensure that the bore in front housing (20) is not damaged as the fuel injection pump is removed.
Remove gasket (18).
If necessary, remove studs (21) from front housing (20).