0439559 JOHNSON POWERHEAD GASKET SET

Table 1
Required Tools
Tool Part Number Part Description Qty
B 276-1216 Injector Pipe Nut Tool 1
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.
Note: The following procedure should be adopted to install the fuel injection lines when the electronic unit injectors or the fuel manifold have not been removed. If the electronic unit injectors or the fuel manifold have been removed, refer to Disassembly and Assembly, "Electronic Unit Injector - Install" and Disassembly and Assembly, "Fuel Manifold - Install" for more information.
Ensure that wiring harness are correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness convoluting.
Illustration 1 g02177629
Remove plugs from fuel manifold (16) and fuel injection pump (23).
Remove the caps from new fuel injection line (22).
Position fuel injection line (22) onto fuel injection pump (23) and fuel manifold (16). Loosely install nuts for the fuel injection line onto the fuel manifold and the fuel injection pump.
Install bolt (24) and bolt (25) to the tube clip finger tight.
Use Tooling (B) to tighten the nuts on fuel injection line (22) to a torque of 55 N m (41 lb ft).
Tighten bolt (24) and bolt (25) to a torque of 10 N m (88 lb in).Note: Ensure that fuel injection lines do not contact any other engine component.
Illustration 2 g02177712
Illustration 3 g02177628
Follow Step 7 through Step 15 to install fuel injection lines for number one cylinder to number three cylinder.
Install new seal (20) to the electronic unit injector and cylinder head (21). Ensure that the flange on the seal is flush with the cylinder head.
Remove the caps from the port of the electronic unit injector and from the appropriate port in fuel manifold (16).
Loosely connect the nuts at both ends of fuel injection line (12) to the electronic unit injector and to the appropriate port in fuel manifold (16). Ensure that the ends of the fuel injection line are correctly seated in the electronic unit injector and in the fuel manifold.
If no further fuel injection lines are to be installed, follow Step 11.a through Step 11.e to assemble clamp (13) and clamp (15) for the fuel injection lines.
Position rubber separator (25) onto the fuel injection lines.
Position clamp (13) and install bolt (14) finger tight.
Tighten bolt (24) and bolt (22) finger tight.
Illustration 4 g02178062
Ensure that dust seal (27) is seated correctly against seal (20).
Use a suitable tool to install tube clamp (15) to fuel injection lines (12).Note: Ensure that the rubber separator is correctly installed to the fuel injection lines. Ensure that the fuel injection lines do not contact any other engine component.
Use Tooling (B) to tighten the nuts on fuel injection line (22) to a torque of 55 N m (41 lb ft).
Follow Step 8 through Step 12 to install the remaining fuel injection lines.
Tighten bolt (14) and bolt (24) for tube clamp (13) to a torque of 10 N m (88 lb in).
Tighten bolt (22) to a torque of 22 N m (195 lb in).
Follow Step 17 through Step 23 to install fuel injection lines for number four cylinder to number six cylinder.
Install new seal (20) to the electronic unit injector and cylinder head (21). Ensure that the flange on the seal is flush with the cylinder head.
Remove the caps from the port of the electronic unit injector and from the appropriate port in fuel manifold (16).
Loosely connect the nuts at both ends of fuel injection line (19) to the electronic unit injector and to the appropriate port in fuel manifold (16). Ensure that the ends of the fuel injection line are correctly seated in the electronic unit injector and in the fuel manifold.
If no further fuel injection lines are to be installed, follow Step 20.a through Step 20.d to assemble clamp (17) for the fuel injection lines.
Position rubber separator (26) onto the fuel injection lines.
Position clamp (17) and install bolt (18) finger tight.
Tighten bolt (23) finger tight.Note: Ensure that the rubber separator is correctly installed to the fuel injection lines. Ensure that the fuel injection lines do not contact any other engine component.
Illustration 5 g02178062
Ensure that dust seal (27) is seated correctly against seal (20).
Use Tooling (B) to tighten the nuts on fuel injection line (22) to a torque of 55 N m (41 lb ft).
Follow Step 17 through Step 23 to install the remaining fuel injection lines.
Tighten bolt (23) and bolt (18) for tube clamp (17) to a torque of 10 N m (88 lb in).Note: Ensure that the rubber separator is correctly installed to the fuel injection lines.
Illustration 6 g02358237
Position a new gasket (11) onto the cylinder head.
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