0435478 JOHNSON GEARCASE ASSY., Complete

1. Remove locknut (3) and the washer. Disconnect lever assembly (2) from the control rod.2. Remove bolts (1), and remove lever assembly (2) from the cylinder head assembly. 3. Remove bolt (5) and clamp (4) that hold the fuel injector in position.
Do not put a force on the fuel injection rack, or cause damage to it when the injectors are removed from the cylinder head assembly.
The inlet fuel line must be removed from the cylinder head assembly before the injectors are removed to prevent fuel leakage into the combustion chambers and the crankcase. Put protective caps on the fuel openings.
If too much fuel leaks into a cylinder, a hydraulic lock will form when the piston moves up during engine start-up. The hydraulic force can be large enough to crack the cylinder head spacer plate.
4. Use a pry bar, and loosen injector (6) from the cylinder head assembly. Pull injector (6) out of the cylinder head assembly, and remove it from the engine. 5. A 6V472 Injector Sleeve is installed on the fuel injectors to prevent contamination from entering the open fuel ports. After cleaning the fuel injector, remove the injector sleeve and O-ring seals (7).6. If necessary, remove the plug from clamp (4) from the cylinder head assembly.Install Fuel Injectors
1. Use tool (A) as shown to make sure the fuel injection rack will move freely by its own weight when injector (6) is turned a total of 180° in both directions. Check the rack movement with the injector spring under compression in several positions.
To prevent a carbon deposit between the injector and the injector bore. Make sure the injector body (especially the tapered area) and the injector bore are clean and free of foreign material.
2. Make sure the three O-ring seals (7) are installed in injector (6), and put 5P960 Multipurpose Grease on the seals and in the bore in the injector.3. Make sure the plug that the anvil of clamp (4) sets on is installed in the top of the cylinder head assembly. Put clean engine oil on the plug and the anvil of clamp (4).
Do not tap or hit on the injector follower to install the injector. Damage and failure of the injector can be the result.
4. Put injector (6) in position in the cylinder head assembly. Install clamp (4), and tighten the bolt and washer to push injector (6) all the way into its bore. Tighten the bolt to a torque of 65 7 N m (48 5 lb ft).5. Check to make sure the fuel injection rack moves freely by hand in the injector after the injector is installed.6. Put lever assembly (2) in position. Connect the lever assembly to control rod (8). Tighten the nut and bolt that fastens the lever assembly to control rod (8) to a torque of 8 2 N m (6 1 lb ft). Make sure lever assembly (2) is engaged correctly with the fuel injection rack. Install the two bolts to hold the lever assembly in place.7. See Testing And Adjusting section for the correct adjustment of the fuel injection control group. Make sure the control group can move to the fuel "OFF" position with the governor linkage disconnected.End By:a. install rocker shaft assemblies and push rods