0434749 JOHNSON GEARCASE ASSY., Std.

start by:a) remove fuel injection lines 1. Use tool (A) and remove fuel filter (1) from the fuel filter base. 2. Remove fuel supply line (2) from the fuel filter base.3. Disconnect drain line (3).4. Remove bolts (4) and (5) that hold the clamps to the fuel injection pump housing.5. Disconnect transfer pump drain line (7) and oil line (6) from the transfer pump. 6. Disconnect tachometer cable (10) from the tachometer drive.7. Disconnect governor linkage (8) from the lever.8. Disconnect tube (9) from the fuel ratio control. The radiator and radiator guard was removed for photo illustration. 9. Remove turbocharger oil return line (11).10. Remove bracket (12) from the fuel injection pump housing and governor and the adapter on the cylinder block. 11. Remove nuts (14) and cover (13) from the front of the timing gear cover. 12. Loosen bolt (15) until there is approximately 3.2 mm (.125 in.) clearance between the bolt head and washer (16).13. Install tooling (A) on the fuel injection pump drive gear and automatic timing advance as shown. Use tooling (A) to loosen the drive gear from the taper.14. Remove tool (A), bolt (15) and washer (16). 15. Fasten a hoist to the fuel injection pump housing and governor. Remove three nuts (17) that hold the fuel injection pump in place. Remove fuel injection pump housing (18) and governor as a unit. The weight is 23 kg (50 lb.).Install Fuel Injection Pump Housing And Governor
1. Put the number one piston in top center compression position. See FINDING TOP CENTER COMPRESSION POSITION FOR NO. 1 PISTON in TESTING AND ADJUSTING.
TYPICAL EXAMPLE SHOWN IN CHASSIS2. Remove bolt (2).3. Remove timing pin (1) (if so equipped) from the cover of the governor housing.4. Put timing pin (1) or tool (A) in the hole for bolt (2). Turn the camshaft until timing pin (1) on tool (A) goes in the notch in the camshaft. 5. Make sure the O-ring seal is in position on the face of the fuel transfer pump. Fasten a hoist and install fuel injection pump housing (3) and governor on the engine. Install the three nuts that hold the fuel injection pump housing to the timing gear plate.6. Put the fuel injection pump drive gear and automatic timing advance in position on the camshaft and install the washer and bolt that hold it. The indicator and radiator guard and fan belts are removed for photo illustration. 7. Install tooling (B) in the holes of the fuel injection pump drive gear as shown. Put a torque of approximately 68 N m (50 lb.ft.) on the pump drive gear in a clockwise direction (as seen from the front of the engine). With the clockwise torque on the pump drive gear, tighten the bolt to a torque of 149 7 N (110 5 lb.ft.).8. Remove timing pin (1) or tool (A). Remove the 3/8"-16 NC bolt from the flywheel.9. Turn the engine counterclockwise (as seen from rear of engine) two complete revolutions. If timing pin (1) or tool (A) goes into the notch in the camshaft of the fuel injection pump and the 3/8"-16 NC bolt goes in the flywheel at the same time, the timing is correct.10. If timing pin (1) or tool (C) can not be installed see CHECKING TIMING BY TIMING PIN METHOD in TESTING AND ADJUSTING. 11. Put the gasket in place and install cover (4) on the timing gear cover. 12. Put the gasket in place and install turbocharger oil return line (5).13. Install bracket (6). 14. Connect tube (8) to the fuel ratio control.15. Connect governor linkage to the lever (7).16. Connect tachometer cable (9) to the tachometer drive. 17. Connect fuel transfer pump drain line (14) to the fuel transfer pump. Connect oil line (15).18. Connect drain line (11) to the fuel injection pump housing.19. Put the clamps in place and install bolts (12) and (13).20. Connect fuel supply line (10) to the fuel filter base. 21. Install fuel filter (16). Follow the instructions on the side of the fuel filter for correct installation.end by:a) install fuel injection lines