0434645 JOHNSON ENGINE COVER, Port

start by:a) remove fuel injection pump housing and governorb) remove governor
Be careful not to cause damage to the inlet and outlet ports on the bottom of the pump housing. The pump housing must be put on wood blocks before it is disassembled.
1. Remove bolts (1), cover (3) and gasket.2. Remove bolts (4), housing (2) and gasket. 3. Remove shaft and gear (5) from housing (2). 4. Remove bearing (6) from housing (2). Bearing (6) must be destroyed to remove. 5. Remove two bolts (8) and remove cover (7). 6. Remove bolts (14) that hold retainer (12) and gear (11) to the pump camshaft. Remove the retainer and gear. When pinion gear (13) is removed, make a replacement of drive gear (10) with a new part.7. Remove idler gear (9). Remove pinion gear (13) from the pump housing with a soft hammer. Remove drive gear (10). 8. Remove felt washers (16). Remove timing pin plug (15). 9. Install tools (B) and (C). Remove bushings (17) with tool (B). A small amount of pressure down on tool (C) will help in removal of bushings (17).10. Put identification on each injection pump as to its location in the pump housing. Hold the fuel racks against tool (A) in the center (zero) position and carefully remove each fuel injection pump with tool (C). 11. Remove the bolt that holds bracket (18) to the pump housing. Remove bracket (18) and link (19). 12. Put identification on fuel racks (20) and (21). Remove the fuel racks. 13. Put identification on each spacer and lifter as to their location in the pump housing. Remove the spacers and lifters (22). 14. Remove camshaft (23) from the pump housing. 15. Remove upper bearing (24) and the lower bearing that hold the pinion gear in the pump housing. 16. Remove the dowel and idler gear shaft from the pump housing with tool group (D).17. Remove bypass valve (26). Remove O-ring seals, pin, piston and spring from the valve body.18. Remove O-ring seal (25). 19. Remove fuel rack bearings (27).20. Remove camshaft bearings (28) with tool group (E).Assemble Fuel Injection Pump Housing
1. Install the camshaft from and rear bearings with tool group (A). Install the front bearing until it is a distance of .04 .02 in. (1.0 0.5 mm) from the front surface of the pump housing. Install the the rear bearing until it is .19 .02 in. (4.8 0.5 mm) from the rear surface of the pump housing. Make sure both oil holes in the bearing are in alignment with the oil holes in the pump housing. 2. Put tool (B) in on the fuel pump housing with the dowels of tool (B) in alignment with the left fuel rack bore. Install the bolt that holds the tool in place on the housing. 3. Put a new bearing (1) in position with the tab of the bearing up. Install the bearing with tool (C) until the shoulder of tool (C) makes contact with tool (B).4. Turn tool (B) and make an alignment of the dowels on tool (B) with the right fuel rack bore.5. Do Step 3 again for the left fuel rack bearing. 6. Install shaft (2) to a height of .66 .02 in. (16.8 0.5 mm) and dowel (3) to a height of .25 .02 in. (6.4 0.5 mm) above the surface of the pump housing. 7. Make sure the chamfer on the lower bearing for the pinion gear is toward the inside and the notch is in the location shown. Install the bearing until it is even with the lower surface of the bearing bore with tooling (D).8. Make sure the chamfer on the upper bearing for the pinion gear is toward the inside and the notch is in the location shown. Install the bearing until it is even with the upper surface of the bearing bore with tooling (D). 9. Install pinion gear (5) in the pump housing. Put the drive gear in position on pinion gear shaft and install cover (4). Install tool (E) and "C" clamp as shown and install pinion gear (5) until drive gear makes contact with the shoulder of the pinion gear shaft. 10. Remove cover (4) and remove any metal chips or shavings that might have been caused when the drive gear was installed on the pinion shaft.11. Install idler gear (6) on the shaft.12. Install cover (4) and the two bolts that hold it in place. 13. Install spring (11), piston (9) and pin (8) in valve body (7). Install O-ring seals (10) on valve body (7).
Pin (8) must not extend out from either side of valve body (7).
14. Put clean engine oil on the valve body and O-ring seals. Install the oil bypass valve in the pump housing. Tighten the valve to a torque of 50 10 lb.ft. (70 14 N m). 15. Put clean engine oil on the camshaft bearings and camshaft (12). Install the camshaft. 16. Install camshaft gear (13) and retainer (14) on the camshaft. 17. Install lifters (16) and spacers (15) in their respective locations in the fuel pump housing. If new lifters and/or spacers are installed, make an adjustment to the fuel pump timing dimension. See SETTING THE INJECTION PUMP TIMING DIMENSION: OFF ENGINE in TESTING AND ADJUSTING. 18. Put clean engine oil on the fuel racks. Install left fuel rack (17) and right fuel rack (18) in the pump housing with the groove in the racks engaged with the tab of the rack bearings. 19. Put link (19) in position over the dowel and in the notch of each fuel rack. 20. Install bracket assembly (20) and the bolt that holds it in place. 21. Install the bearing in housing (21) with tooling (D). 22. Install gasket and cover (22).23. Put shaft and gear assembly (24) in position in the retainer on the end of the camshaft.24. Install gasket (23) and housing (21) on the fuel pump housing. 25. Install