0284583 JOHNSON ENGINE COVER ASSY., 200

Table 1
Required Tools(1)
Tool Part Number Description QTY
A 128-8823 Long Nose Pliers 1
B 9U-7282 Indicator Fixture Group 2
C 8T-4177 Bolt 2
D 9U-7263 Indicator Contact Point 2
E 1U-8869 Dial Indicator (Digital) 2
F 1U-6673 Wrench (Fuel Ratio Control) 1
(1) Actual tooling may vary depending on the individual engine arrangement.The following procedure may be used to synchronize the unit injectors and the following procedure may be used to adjust the unit injectors.
Stop the engine and turn the electrical system to the OFF position.
Remove the fuel shutoff solenoid. Note: If the fuel shutoff solenoid is inaccessible, the following steps may be followed.
Turn the engine start switch to the ON position. Briefly engage the starter. Do not start the engine. Return the engine start switch to the ON position. Do not turn the engine start switch to the OFF position.
Turn the battery disconnect switch to the OFF position or disconnect the negative terminal of the battery. This will leave the fuel shutoff solenoid in the OPEN position.
Remove the valve cover.
Illustration 1 g00998517
Remove bolts (1) that attach the valve mechanism cover base.
Illustration 2 g00998519
Attach Tooling (A) to the rail for the fuel (2).
Illustration 3 g00998587
Install Tooling (B) in hole (3) for the valve mechanism cover base that is near the No. 1 cylinder. Attach Tooling (D) to Tooling (E). Insert Tooling (E) into the hole in Tooling (B). Note: Orient face (4) on Tooling (B) parallel to the crankshaft.
Install the other Tooling (B) in hole (3) for the valve mechanism cover base that is near the No. 2 cylinder. Attach Tooling (D) to Tooling (E). Insert Tooling (E) into the hole in Tooling (B). Note: Orient face (5) on Tooling (B) parallel to the crankshaft.
When the engine is viewed from the flywheel end, rotate Tooling (A) in a counterclockwise direction. You should feel resistance to a spring. Turn Tooling (A) past the start of the resistance of the spring. Zero out Tooling (E) for both the injectors. Note: Do not turn Tooling (A) all the way. This will lead to an inaccurate synchronization.
When the engine is viewed from the flywheel end, rotate Tooling (A) in a clockwise direction through the entire range of motion. The readings on Tooling (E) should change as the position of Tooling (A) is changed. Take a note of the values and of the difference in the values.
Illustration 4 g00998590
If the values are within a tolerance of 0.05 mm (0.0020 inch), no adjustment is required. If an adjustment is required, install Tooling (F) on the locknut at the base of the unit injector.
Illustration 5 g00998591
Loosen the locknut with the outer rod (6) and adjust the injector with the inner rod (7). Tighten the locknut when the adjustment is complete.
Repeat Step 8 through Step 11. Illustration 4 shows two unit injectors that have been properly synchronized.
Once the first two injectors have been synchronized, synchronize the remaining injectors by following the previous procedure. Remove Tooling (B) from the No. 2 cylinder and move to the No. 3 cylinder. Do not move Tooling (B) from the No. 1 cylinder. Always synchronize the injectors with the first injector. The first injector is the reference point for all the injectors.
Once all the injectors have been synchronized, remove all the tooling from the engine. Install bolts (1) that attach the air intake housing. Replace the valve cover and tighten the bolts that attach the valve cover. Refer to Specifications, "Valve Mechanism Cover" for instructions.