5035366 JOHNSON SPRING, CLUTCH DOG SHIFTER

Table 1
Required Tools
Tool Part Number Part Description Qty
A 276-1216 Injector Pipe Nut Tool 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Do not let the tops of fuel injectors turn when the fuel line nuts are loosened or tightened.The fuel injectors will be damaged if the top of the injector turns in the body.The engine will be damaged if a defective fuel injector is used because the shape of fuel (spray pattern) that comes out of the nozzle will not be correct.
Note: Place identification marks on all tube assemblies for installation. Plug all lines and tube assemblies in order to prevent contamination.
Turn the fuel supply to the OFF position.
Illustration 1 g03341354
Use Tooling (A) to disconnect nuts (1) for fuel injection lines (3) from fuel injectors (2).
Use Tooling (A) to disconnect nuts (4) for fuel injection lines (3) from fuel injection pump (5).
Remove fuel injection lines (3) from the engine as an assembly.
Use suitable caps in order to plug the open ports of fuel injection pump (5) immediately.
Use suitable caps in order to plug the open ports of fuel injectors (2) immediately.
Illustration 2 g03341356
If fuel injectors (2) have been previously capped, the caps will need removing from fuel injectors (2) before removing nuts (7).
Use a deep socket in order to remove nuts (7) from fuel injectors (2). Note: For engines with a fuel return line, ensure that the fuel return line is not distorted when the nuts are loosened.
Remove banjo bolt (9) from fuel return line (6).
Remove sealing washers (10).
Remove fuel return line (6) from fuel injectors (2).
Remove sealing washers (8) from fuel injectors (2).
Use suitable caps in order to plug fuel injectors (2) immediately. Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A 276-1216 Injector Pipe Nut Tool 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Do not let the tops of fuel injectors turn when the fuel line nuts are loosened or tightened.The fuel injectors will be damaged if the top of the injector turns in the body.The engine will be damaged if a defective fuel injector is used because the shape of fuel (spray pattern) that comes out of the nozzle will not be correct.
Note: The installation procedure is similar for the three cylinder and the four cylinder engines.
Illustration 3 g03341356
Remove the caps from fuel injectors (2).
Install new sealing washers (8) to fuel injectors (2). Note: The sealing washers have two small holes.
Install fuel return line (3) onto fuel injectors (2).
Use a deep socket in order to install nuts (7) loosely to fuel injectors (2).
Install a new sealing washer (10) onto banjo bolt (9).
install banjo bolt (9) to rigid fuel return line (6).
Install remaining new sealing washer (10) between rigid fuel return line (6) and the connection on the fuel injection pump.
Tighten banjo bolt (9) hand tight.
Use a deep socket in order to tighten nuts (7) to a torque of 27 N m (239 lb in).
Tighten banjo bolt (9) to a torque of 10 N m (89 lb in).
Illustration 4 g03341354
Remove the caps from fuel injection pump (5).
If necessary, the caps from fuel injectors (2).
Position fuel injection lines (3) onto the engine as an assembly.
Install fuel injection lines (3) to fuel injectors (2) and fuel injection pump (5).
Tighten nuts (1) and nuts (4) for fuel injection lines (3) hand tight. Ensure that the ends of the fuel injection line are correctly seated in the fuel injectors and in the fuel injection pump.
Use Tooling (A) in order to tighten nuts (4) for fuel injection lines (3) to a torque of 23 N m (204 lb in).
Use Tooling (A) in order to tighten nuts (1) for fuel injection lines (3) t