0435500 JOHNSON GEARCASE ASSY., Complete

start by:a) remove air inlet manifoldb) remove fuel injection lines 1. Remove nuts (1) that hold the tachometer drive adapter in place. The tachometer drive adapter is just above the water pump pulley. 2. Use tooling (A) to remove tachometer drive adapter (2). 3. Remove tachometer drive shaft (3) and the washer that hold the drive gear on the fuel injection pump camshaft. 4. Use tool (B) to loosen the drive gear on the camshaft. 5. Close the fuel shutoff valve at the water separator fastened to the hydraulic tank. Remove fuel supply lines (4) and (6). Remove fuel return line (5). 6. Disconnect the governor control cable from lever (7) on the governor.7. Remove two bolts (8) that hold the fuel injection pump housing and governor to the cylinder block. Slide the fuel injection pump housing and governor to the rear of the engine and remove.Install Fuel Injection Pump Housing And Governor
1. Install tool (B) in the fuel injection pump camshaft. Remove the plug from the cover on the fuel injection pump housing and install tool (A). Use tool (B) to turn the camshaft until the timing pin (A) can be pushed into the groove (slot) in the fuel injection pump camshaft.2. Be sure O-ring seal (1) and the O-ring seal on the bottom of the governor housing are in place. 3. Put fuel injection pump housing and governor (2) in position on the engine. 4. Install bolts (3) that hold the fuel injection pump housing and governor to the cylinder block.5. Connect the governor control cable to the top hole in lever (4). 6. Install the washer and tachometer drive shaft (5) but do not tighten shaft (5). 7. Remove the starter and install tooling (C) in the flywheel housing to turn the engine. 8. Remove cap (6) and the fitting from the front of the timing gear cover. 9. Install a 5/16"-18 NC bolt (7) 2 1/2 in. long. The cover bolt from hole (8) can be used. Use tooling (C) to turn the crankshaft clockwise (as seen from front of engine) until bolt (7) can be installed into the camshaft gear and is in the center of the timing hole. With timing pin (A) in the groove (slot) in the fuel injection pump camshaft and bolt (7) in the hole in the engine camshaft gear, the timing for the engine is correct. Tighten tachometer drive shaft (5) to a torque of 149 14 N m (108 10 lb.ft.).10. To check the timing, remove timing pin (A) and bolt (7). Turn the crankshaft with tool (C) clockwise (as seen from front of engine) two revolutions and install the timing pin (A) and then bolt (7) back in place. If bolt (7) can not be installed, the timing is not correct and the procedure must be done again. Do not turn the crankshaft counterclockwise (as seen from the front of the engine) to install bolt (7). The drive gear on the fuel injection pump camshaft must be loosened to change the timing. 11. When the timing is correct, put engine oil on the O-ring seal on tachometer drive adapter (9) and install the adapter over the tachometer drive shaft. 12. Remove the bolt from the engine camshaft gear and install the fitting and cap (10) in the timing gear cover. 13. Remove timing pin (A) and install the plug in the cover on the fuel injection pump housing.14. Install fuel supply lines (11) and (13). Install fuel return lines (12). Open the fuel shutoff valve at the water separator fastened to the hydraulic tank.end by:a) install air inlet manifoldb) install fuel injection lines