0435959 JOHNSON IMPELLER HOUSING, Gearcase

Step 1. Install The Timing Adapter GroupA. Turn the engine off at the ignition switch.
Magnetic Pick-up Sensor
(1) Magnetic pick-up sensor. (2) Adapter sleeve for magnetic pick-up.
Timing Adapter Module Installed On ECAP
(3) ECAP. (4) Timing adapter module. (5) Cable for magnetic pick-up.B. Install the 8C9995 Module Adapter Plate on the ECAP. Install timing adapter module to the module adapter plate. Connect cable for the magnetic pick-up to the timing adapter module.C. Use the Turning Tool to put either #1 or #6 piston at top-dead-center on the compression stroke.
Electronic Control System Components
(6) Port for timing calibration probe. (7) Speed/Timing Sensor.D. Remove the Timing Calibration Plug from the right side of the cylinder block (on the #4 cylinder rod pocket) and install the Timing Probe Adapter Sleeve into the hole.
Installed Magnetic Pick-up Sensor
(1) Magnetic pick-up sensor. (2) Adapter sleeve for magnetic pick-up. (8) Counterweight. (9) TDC slot. (A) 1.0 mm (.040 in).E. Rotate the engine until #1 cylinder is between 10 and 90 degrees before-top-dead-center (BTDC). This positions the counterweight surface in front of the timing calibration hole. The counterweight must be a minimum of 10 degrees BTDC to make sure the timing probe is positioned on counterweight surface and not TDC slot.
If the crankshaft is not in the correct position when the magnetic pickup sensor is installed, the magnetic probe will be damaged when the engine is started.
F. Put a 2D6392 O-Ring Seal on the end of the Magnetic Pick-up Sensor (a small amount of clean engine oil will let the seal slide onto the sensor more easily).G. Push the sensor through the adapter until it comes in contact with the counterweight and move the O-Ring Seal down against the adapter.H. Withdraw the sensor 1 mm (.04 in.) and hand tighten the nut on the adapter sleeve to firmly hold the timing probe in position.I. Connect cable for magnetic pick-up to the magnetic pick-up sensor. Step 2. Install ECAP And Injector HarnessA. Connect an ECAP to the Engine Data Link Connector (J8).B. Install the Injection "T" Harness on the Fuel Injector Connector (J5/P5) in the valve cover base.C. Be certain all connections (probe, harness, ECAP) are made correctly. Use special care when connecting "T" Harness to J5. The plug can be mis-aligned. Also use care when reconnecting J5 and P5. Incorrect installation will result in a "No Start" condition. Step 3. Calibrate Speed/Timing SensorA. Start the engine and run at low idle until the engine has warmed up enough to change out of Cold Mode operation. The "Diagnostic Lamp" should go out after the engine has started and the 10 second lamp test is complete. The engine rpm will decrease from approximately 1000 rpm while in the cold mode to the programmed low idle rpm when out of Cold Mode.B. Check for ACTIVE Diagnostic Codes. Use the procedures in this manual to troubleshoot and repair any ACTIVE Diagnostic Codes before attempting a calibration check.C. After engine has shifted out of Cold Mode, select the 3176 Timing Calibrate Screen on the ECAP. To insure the most accurate timing calibration, the engine rpm should be held as steady as possible at approximately 1500 rpm. This can be performed using the hand throttle. Any major changes (greater than 100 rpm) will slow down the procedure and make it less accurate.D. Press on the "space" key on the ECAP and wait until the ECAP indicates timing is CALIBRATED (approximately 15 seconds).E. Verify that timing has been calibrated by observing the "Desired Timing" bar display on the ECAP. Run the engine at different rpm's, allowing a few seconds at each setting for the rpm to stabilize. * If the ECAP display reads that injection timing is CALIBRATED, but during verification, the actual timing bar display is not within the two vertical timing tolerance lines and/or the display is erratic, repeat the timing calibration procedure.* If the ECAP display reads UNABLE TO CALIBRATE TIMING, the electronic injection timing has NOT been set. OK: Timing is functional and calibrated if the right end of the bar graph display stays within the vertical bars at all steady speeds. NOT OK: Recheck the tool installation and tool operation. Verify that the engine speeds were kept stable ( 50 rpm) during testing. If engine speed was unstable or could not be controlled within 50 rpm because of mechanical or electrical factors, refer to P-103: Engine Misfires, Runs Rough Or Is Unstable. NOT OK: If all of the above checks are OK but the timing still will not calibrate, refer to P-221: Engine Speed/Timing Signal Test in this manual.P-302: Boost Pressure Sensor Calibration
The 3176 Boost Pressure Sensor must be calibrated for a zero boost condition with the engine OFF. Calibration is accomplished electronically without need for manual adjustments.The sensor must be recalibrated whenever the transducer module or ECM has been replaced. Incorrect sensor calibration may result in poor engine response or a Diagnostic Code 25 (Boost Pressure Sensor Fault) or a Diagnostic Code 42 (Check Sensor Calibration). Calibration Procedure:1. Start engine and warm up to normal operating temperature, then turn key OFF.2. Turn key ON (engine off). The sensor will not calibrate if the engine is running.3. Select the Boost Sensor Calibration screen on the ECAP or DDT (see the Special Instructions included with the ECAP or DDT).4. Wait several seconds for the automatic calibration to occur. The screen will display "Calibrated" when finished.5. If the boost pressure sensor will not calibrate, follow P-225: Boost Pressure Sensor Test.P-303: Throttle Position Sensor Adjustment
The Throttle Position Sensor (TPS) is used to provide a throttle signal to the Electronic Control Module (ECM).Sensor output is a constant frequency signal whose pulse width varies with throttle position. This output signal is referred to as either "Duty Cycle" or a "Pulse Width Modulated (PWM)" signal and is expressed as a percentage. When correctly adjusted, the "Remote