0787030 JOHNSON Service Manual

Table 1
Required Tools
Tool Part Number Part Description Qty
B 130-6993 Injector Seat Cleaning Brush 1
C 5P-0328 Wrench(1) 1
D 5P-0329 Wrench(1) 1
E 1P-0808 Multipurpose Grease -
(1) The wrench is part of the 9U-5106 Diesel Engine Tool Group.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Remove the protective plug in the unit injector opening. Carefully insert a screwdriver with a long blade through the unit injector opening until the screwdriver contacts the top of the piston. Withdraw the screwdriver, and check for the presence of fuel or engine oil on top of the piston. If present, use an oil sampling vacuum withdraw pump in order to remove the accumulation. Large liquid accumulation can cause a hydraulic lock and engine damage.
Illustration 1 g03745021Check torque of studs (9). Tighten stud (9) to a torque of 50 5 N m (37 4 lb ft).
Illustration 2 g01299165Note: Do not turn the trim screw while the fuel injector is being installed. The trim screw is used to calibrate the fuel injector in the factory. If the fuel injector has a loose trim screw, the fuel injector must be replaced.
Install new seals on fuel injector (6). The serrated portion of the flat seal must not line up with the coolant ports in the cylinder head. Note: The serrated seal is used with fuel injectors for engines that use heavy fuel oil. Other fuel injectors may not have a serrated seal.
Apply clean engine oil to the seals.
Use Tooling (B) and use a hand drill to clean the bore for the fuel injector in the cylinder head.Note: Apply Tooling (E) to the bore of the cylinder head for lubrication of the O-ring seals.
Do not let the tip of the unit injector contact any components. Damage to the tip will make replacement of the unit injector necessary.
Carefully place fuel injector (6) into the cylinder head. Be sure that dowels (7) on the fuel injector are around the bridge dowel. Be sure that the notch in fuel rack (8) engages with the round bolt in the fuel rack lever.
Illustration 3 g03745079
Do not tap on the top of the unit injector in order to seat the unit injector in the bore. Damage to the tip can occur. This will make replacement of the unit injector necessary.
Note: Be sure that the top surface of the clamp is parallel to the top surface of the cylinder head within 2.0 mm (0.08 inch).
If the clamp is not centered around the injector spring, contact between the spring and the clamp can occur when the engine is running. This could result in broken injector springs or hold-down clamp studs.
Do not reuse the injector clamp hold down nuts (5). Install new injector clamp hold down nuts (5) each time the injector is removed.
Install unit injector clamp (4) and nuts (5). Tighten nuts (5) evenly to move the fuel injector into position. Tighten nuts (5) to a torque of 35 5 N m (26 4 lb ft).
Inspect the area between the side of the fuel injector spring and the hold-down clamp. The clamp should be centered on the spring. The distance between the spring and the clamp must be approximately equal around the spring.
If the clamp is not centered on the spring, remove the nuts (5) that hold the clamps in place. Rotate the clamp for 180 degrees (1/2 turn) and repeat Steps 4 and 5.
After the nuts (5) are tightened, the lever and the fuel rack must move freely.
Synchronize the fuel control linkage. Refer to Testing and Adjusting, "Fuel Injector Synchronization".
Illustration 4 g01298982
Remove the protective caps and install fuel supply tube assembly (3) and fuel return tube assembly (2).