0385354 JOHNSON GEARCASE ASSEMBLY, Less driveshaft & pump

Table 1
Required Tools
Tool Part Number Part Description Qty
A 298-5564 T40 Torx Socket 1
B 268-1968 Pry Bar 1
C 370-8376 Cap Kit 1 Start By:
Remove the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker Shaft - Remove" for the correct procedure.
Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove" for the correct procedure.
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 authorised personnel that have the correct training.Before begining 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 Systems Operation, Testing and Adjusting Manual, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Use a deep socket in order to remove the electrical connections from the electronic unit injectors. Use of incorrect tooling will result in damage to the electronic unit injectors.
Note: Place identification marks on all hoses, on all hose assemblies, on wires and on all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. Plugging all hose assemblies and tube assemblies will prevent fluid loss. Plugging all hose assemblies and tube assemblies will to keep contaminants from entering the system.
Turn the fuel supply to the OFF position.
Turn the battery disconnect switch to the OFF position.
Illustration 1 g01971774
Place a suitable container below tube assembly (1) in order to catch any fuel that might be spilled.
Loosen the nut on hose assembly (3) in order to allow the fuel to drain from tube assembly (1).
Remove hose assembly (3) from tube assembly (1). Remove O-ring seal (2).
Use Tooling (C) in order to cap the hose assembly immediately. Use Tooling (C) in order to plug the tube assembly immediately.
Illustration 2 g01971773
Make a temporary mark on valve bridges (5) in order to show the location and orientation. Remove valve bridges (5). Note: Identification will ensure that the valve bridges can be reinstalled in the original location and the original orientation.
Remove seal (4) from the cylinder head and electronic unit injector (8).
Make a temporary mark on wiring harness assembly (6) in order to show the location and orientation.
Use a deep socket to remove connections (7) from electronic unit injector (8).
Use Tooling (A) in order to remove Torx screw (9) from clamp (10). Discard the Torx screw. Note: Tooling (A) must be used to ensure no damage to the electronic unit injector.
Illustration 3 g01971775
Illustration 4 g01972153
Make a temporary mark on electronic unit injector (8) in order to show the original location of the electronic unit injector.
Temporarily remove Tooling (C) from the electronic unit injector.
Use Tooling (B) to pry beneath clamp (10) and free electronic unit injector (8) from the cylinder head. Note: Always handle electronic unit injectors with care.
Immediately replace Tooling (C) onto the electronic unit injector.
If electronic unit injector (8) is to be reused, Follow Step 17 through Step 19 in order to remove sealing washer (12) and O-ring seal (11).
Use a suitable tool in order to remove sealing washer (12) from electronic unit injector (8). Ensure that the sealing washer is removed from the cylinder head. Note: Ensure that the nozzle for the electronic unit injector is not damaged in any way on removal of the sealing washer.
Install Tooling (C) to the nozzle for electronic unit injector (8) and the open port of the electronic unit injector.
Remove O-ring seal (11) from electronic unit injector (8).
If necessary, repeat Step 7 through Step 19 in order to remove the remaining electronic unit injectors.
Illustration 5 g02311716
If necessary, follow Steps 21.a through 21.f in order to remove harness assemblies (6) from cylinder head (16).
Cut cable straps (13).
Unscrew the remaining sections of