5005838 JOHNSON *MOTOR & O-RING ASSY

Table 1
Required Tools
Tool Part Number Part Description Qty
B - Delphi Lockheed Rubber lube LPK94 1
C 1U-5718 Vacuum Pump 1
169-7372 Fluid Sampling Bottle 1
4C-4057 Tube
7.9 mm (0.31 inch) Outside Diameter 1
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct training.Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information.Refer to Systems Operation, Testing and Adjusting Manual, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Note: When installing electronic unit injectors, the electronic unit injectors must be installed in pairs.
Ensure that the electronic unit injectors are free from wear and damage. Replace any electronic unit injector that is worn or damaged.
Illustration 1 g06157096
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If necessary, apply Tooling (B) to the internal diameter of new seals (10). Use suitable tooling to install the seals to valve mechanism cover (9). Ensure that the seals are not damaged and are correctly seated into the valve mechanism cover.
Install new studs (11). Tighten the studs to a torque of 44 N m (32 lb ft).
Illustration 3 g06157081
Illustration 4 g06159056
Injector code in Position (X)
Ensure that the bores for electronic unit injectors (4) in the cylinder head are clean and free from wear and damage.
If the original electronic unit injectors are to be installed, ensure that the electronic unit injectors are installed into the original location.
If the original electronic unit injectors (5) are to be reused. Install a new O-ring seal (7) to the electronic unit injectors. Remove the protective cap from the nozzle and install a new sealing washer (8). Temporarily reinstall the protective cap from the nozzle.
If replacement electronic unit injectors (4) are installed, the correct Injector codes must be programmed into the electronic control module. The codes are 30 hexadecimal characters in length and are supplied with each injector. The code is on a plate on the top of the injector in Position (X) and a card is also included in the packaging for the new injector. Refer to Troubleshooting, "Injector Code - Calibrate" for more information.
Use Tooling (C) to remove any fuel from the cylinder bore.Note: Evacuate as much fuel as possible from the cylinder bore before installing the electronic unit injectors.
Install new injector clamp (3) to electronic unit injectors (4).
Install the electronic unit injectors to the cylinder head. Ensure that the electronic unit injectors are installed squarely into the cylinder head. Push the electronic unit injectors into the cylinder head. Always handle electronic unit injectors with care.
Install new nut (2) to injector clamp (3). Tighten the nut to a torque of 10 N m (89 lb in) to seat the electronic unit injectors into the cylinder head.
Loosen nut (2) by two to three turns.
Install new fuel injection lines (6) hand tight the tube nuts.
Tighten new nut (2) to a torque of 28 N m (248 lb in)
Tighten the tube nuts for fuel injection lines (6). Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure.
If necessary, follow Step 5 through Step 15 to install remaining electronic unit injectors (4).
Illustration 5 g06157074
Illustration 6 g06385225
Install new O-ring seal (13) to leak off hose assemblies (1).
Connect leak off hose assemblies (1) to electronic unit injectors (4). Ensure that the leak off hose assemblies is correctly installed into electronic unit injectors (4).
Install new clips (12) to leak off hose assemblies (1). Ensure that the clips are correctly located onto electronic unit injectors (4).
Connect harness assemblies (5) to the electronic unit injectors.
If necessary, follow Step 17 through Step 20 to install remaining leak off hose assemblies (1) and harness assemblies (6) to remaining electronic unit injectors (4).
Turn the fuel supply to the ON position.
Turn the battery disconnect switch to the ON position.
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.