0382793 JOHNSON GEARCASE ASSEMBLY

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-1860 Retaining Ring Pliers 1 Start By:
Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".
Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove".
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01342484
Place a temporary identification mark on connections (1) for harness assembly (4).
Use a deep socket to remove connections (1) from electronic unit injectors (2).
If necessary, follow steps 3.a through 3.f in order to remove harness assemblies (4) from valve mechanism cover base (7).
Cut cable strap (3).
Disconnect plug (6) from harness assembly (4).
Use Tooling (A) to remove circlip (5).
From the outside of valve mechanism cover base (7), push harness assembly (4) inward. Withdraw the harness assembly from valve mechanism cover base (7).
Remove O-ring seal (8) from harness assembly (4).
Repeat steps 3.b through 3.e in order to remove the remaining harness assemblies.
Illustration 2 g01342485
Illustration 3 g01342487
Loosen isolated screws (9) in reverse numerical order. Refer to illustration 3. This will help prevent distortion of valve mechanism cover base (6).
Remove valve mechanism cover base (7) from the cylinder head.
Remove isolated screws (9) from valve mechanism cover base (7).
Remove seal (10) from valve mechanism cover base (7). Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A 1P-1860 Retaining Ring Pliers 1
B 1U-6396 O-Ring Assembly Compound 1
C 247-5377 Torque wrench 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Clean the valve mechanism cover base. Ensure that the mating surfaces are free from damage.
Illustration 4 g01342485
Install seal (10) to valve mechanism cover base (7). Ensure that seal (10) is seated correctly in the groove in the machined face of valve mechanism cover base (7).
Install isolated screws (9) to valve mechanism cover base (6).
Illustration 5 g01342487
Position valve mechanism cover base (7) on the cylinder head. Tighten isolated screws (9) to a torque of 9 N m (79 lb in) in the sequence that is shown in illustration 5.
Illustration 6 g01342484
If necessary, install the harness assemblies for the electronic unit injectors. Follow steps 5.a through 5.h in order to install the harness assemblies for the electronic unit injectors.
Ensure that harness assembly (4) and the bore in valve mechanism cover base (7) are clean and free from damage. Replace any damaged components.
Use Tooling (B) to lubricate a new O-ring seal (8). Install the new O-ring seal (8) onto harness assembly (4).
From the inside of valve mechanism cover base (7), push harness assembly (4) into valve mechanism cover base (7).
Use Tooling (A) to install circlip (5).
Connect plug (6) to harness assembly (4).
Use a deep socket to connect harness (4) to electronic unit injectors (2). Use Tooling (C) to tighten connectors (1) to a torque of 2.4 N m (21 lb in).
Install a new cable strap (3) to harness assembly (4). Note: Ensure that cable strap to OE specification.
Repeat steps 5.a through 5.g for remaining harness assemblies (4). End By:
Install new fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install".
Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".