0383290 JOHNSON OWNERS MANUAL

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 9U-6198 Crankshaft Turning Tool 1
A(2) 9U-7336 Housing 1
5P-7305 Engine Turning Tool 1
B 136-4632 Engine Timing Pin 1
268-1966 Adaptor 1
C 364-9107 Fuel Pump Locking Pin 1
D 370-8376 Capping Kit 1
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.Start By:
If necessary, remove the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install" for the correct procedure .
If necessary, remove the fuel priming pump. Refer to Disassembly and Assembly, "Fuel Priming Pump - Remove" for the correct procedure. Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning 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 System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Turn the fuel supply to the OFF position.
Turn the battery disconnect switch to the OFF position.
Illustration 1 g01967536
Use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead center position . Refer to System Operation, Testing and Adjusting, "Fuel Injection Timing - Check". Use Tooling (B) in order to lock the crankshaft so that number one piston is at top dead center position.
Remove plug (8) and remove O-ring seal (9) (not shown). Use Tooling (C) in order to lock fuel injection pump (10).
Place a suitable container below fuel injection pump (10) in order to catch any fuel that might be spilled.
Clean fuel injection pump (10) and the area around the fuel injection pump. Ensure that the area is free from contamination before beginning disassembly.
Loosen banjo bolt (7) in order to drain fuel from the fuel system. Remove banjo bolt (7). Remove sealing washers (6) and disconnect hose assembly (12) from fuel injection pump (10). Use Tooling (D) in order to plug the tube assembly with a new plug. Cap the port in the fuel injection pump with a new cap.
Disconnect plastic tube assembly (2), plastic tube assembly (4), and plastic tube assembly (5) from fuel injection pump (10).
Use Tooling (D) in order to plug the plastic tube assemblies. Cap the ports in the fuel injection pump with new caps.
Disconnect harness assembly (3) from the solenoid on fuel injection pump (10). Note: The harness assemblies should be positioned in order to avoid an obstruction to the fuel injection pump.
Disconnect harness assembly (1) from the sensor on fuel injection pump (10).
Remove fuel injection line (11) that connects fuel injection pump (10) to the fuel manifold. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove" for the correct procedure. Note: Discard the fuel injection line.
Use Tooling (D) in order to plug the open ports in the fuel injection pump and in the fuel manifold.
If necessary, remove the accessory drive. Refer to Disassembly and Assembly, "Accessory Drive - Remove and Install" for the correct procedure.
Illustration 2 g01967538
Remove nuts (13) and bolts (18) from fuel injection pump (10).
Remove Bolt (15) and spacer (14) from fuel injection pump (10). Note: The fuel injection pump should be supported by hand as the bolts are removed.
Carefully remove fuel injection pump (10) from front housing (16).
Remove gasket (17 ) (not shown).
If necessary, remove the fuel injection pump gear and adaptor plate. Refer to Disassembly and Assembly, "Fuel Injection Pump Gear - Remove" for the correct procedure.