5034966 JOHNSON **HOSE, BYPASS AIR

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Clean Engine Oil 1
C 1U-5718 Vacuum Pump 1
169-7372 Fluid Sampling Bottle 1
4C-4057 Tube
7.9 mm (0.31 inch) OD 1
D 4C-5552 Large Bore Brush 1
E 4C-6774 Vacuum Gun Kit 1
F 8T-7765 Surface Reconditioning Pad 1
G 9U-6862 Tapered Brush
9U-7237 Brush Extension
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Use Tooling (C) to remove the fuel and oil from the cylinder. Evacuate as much fuel and oil as possible from the cylinder before installing the electronic unit injector. Several evacuations may be necessary.
Illustration 1 g03718000
Use Tooling (D) to clean the carbon deposit from the inside the electronic unit injector sleeve at Location (Z). Tooling (E) is available to clean loose material from the bore of the electronic unit injector sleeve and the cylinder.
Illustration 2 g03722826
Section view.
Use Tooling (F) to clean the carbon from the seat area at location (Y) that is inside the electronic unit injector sleeve.
Illustration 3 g03722522
Use Tooling (G) to clean injector seating area (8) and injector tip bore (9).
Illustration 4 g03718585
Use a lint free material to clean O-ring seals (7) and electronic unit injector (2).
Lubricate the top two O-ring seals (7) with Tooling (A). Do not use any other lubricant.Note: Once O-ring seals (7) are lubricated, install immediately.Note: Do not reuse O-ring seals (7).Note: O-ring seals (7) must be stored properly to prevent contamination.
Install O-ring seals (7) on the electronic unit injector.Note: Caution must be taken to avoid overstretching the O-ring seals (7).
Illustration 5 g03729389
Illustration 6 g01135876
When you install a new injector, the E-Trim value must be programmed into the engine control module. The injector confirmation code may need to be programmed into the engine control module. E-Trim Value (X) is a 12-digit alphanumeric code that is supplied with the data sheet that comes with the new injectors. Injector Confirmation Code (Y) is a four-digit numeric code. Both of the codes are on the top of electronic unit injector (2). Use the following menu to program the E-Trim value.
ECM Summary Screen
Service Menu
Calibration
Injector Code Calibration
When an electronic unit injector is replaced, the new electronic injector code must be programmed into the engine's personality module software by using the calibration menu on the Electronic Service Tool. If the new electronic injector code is not entered, the characteristics of the previous electronic unit injector is assumed.If it is not possible to immediately reprogram the electronic injector code into the personality module software, the engine will not be severely harmed. The new electronic injector code should be reprogrammed as quickly as possible in order to optimize engine performance.
Assemble electronic unit injector (2) with the clamp (6), spacer (5), and new bolt (4). Position electronic unit injector (2) in the injector bore.Note: Caution must be used to avoid damaging O-ring seals (7) are not damaged when positioning electronic unit injector (2) in the injector bore.Note: Do not push or manually force electronic unit injector into the bore.
Tighten bolt (4) to a torque of 55 10 N m (41 7 lb ft). Ensure that electronic unit injector (2) is aligned in the bore while tightening bolt (4).Note: Tighten bolt (4) at a slow and uniform rate. If a pneumatic or electric tool is used, care must be taken to avoid damage to the O-ring due to quickly seating the injector.Note: Tightening bolt (4) to correct torque will properly seat electronic unit injector (2).
Inspect area around the bore for electronic unit injector (2) to ensure that O-ring seals (7) were not damaged or extruded.
Install bridge assemblies (3).
Connect harness assembly (1). Tighten the nuts to a torque of 2.5 0.25 N m (22 2 lb in).End By:
Install the rocker arms and the rocker arm shaft.