0395207 JOHNSON STARTER MOTOR ASSY.

Introduction
Do not perform any procedure in this special instruction until you have read this information and you understand this information. This procedure is applicable to configurations that have the main line installed directly to the ARD head without the check valve.Required Parts
Table 1
361-3924 Combustion Head Kit    
Qty     Part Number     Description    
2     296-7780     Gasket    
1     353-9958     Combustion Head As    
1     361-4651     Check Valve As    Procedure
Illustration 1 g02174529
ARD combustion head (1) Spark plug (2) Wire for the heated nozzle (3) Flame detection temperature sensor
Remove spark plug (1) from the old ARD combustion head.
Remove flame detection temperature sensor (3) .
Remove wire for the heated nozzle (2) from the old head.
Remove the ARD combustion head. Refer to the Disassembly and Assembly Manual, "Combustion Head Group (ARD) – Remove and Install (Clean Emissions Module)".
Illustration 2 g02173966
(4) Gaskets (5) Studs
Remove gaskets (4).
Install new gaskets (4) .
Apply 4C-5597 Anti-Seize Compound to the threads of studs (5).
Install the ARD combustion head. Refer to the Disassembly and Assembly Manual, "Combustion Head Group (ARD) – Remove and Install (Clean Emissions Module)".
Apply 4C-5597 Anti-Seize Compound to nuts (6). Tighten the nuts in a crisscross pattern to a torque of 23 3 N m (17 2 lb ft). Tighten nuts (6) again in a crisscross pattern to a torque of 28 3 N m (21 2 lb ft).
Illustration 3 g02174916
(7) Gasket for the ARD combustion air
Install a new gasket for the ARD combustion air (7) .
Install the spark plug (1) from the old combustion head into the new combustion head. Torque the spark plug to 47.5 4 N m (35 3 lb ft).
Install flame detection temperature sensor (3) into the new combustion head. Torque the temperature sensor to 45 5 N m (33 4 lb ft).
Install wire for the heated nozzle (2) into the new combustion head with the hardware from the old combustion head.
Illustration 4 g02175353
Typical example (8) Pilot fuel fitting (9) Main fuel fitting (10) Coolant ports
Install the ARD coolant lines in the coolant ports (10). Tighten the lines to a torque of 12 1 N m (9 1 lb ft).
Illustration 5 g02173895
(11) 361-4646 Check Valve As (12) 361-4651 Check Valve As
Remove the current adapter (11) from the ARD head assembly and install the new adapter (12) Tighten the adapter to a torque of 28 3 N m (21 2 lb ft).
Install the ARD pilot fuel line onto pilot fuel fitting (8). Tighten the line to a torque of 20 N m (15 lb ft).
Install the ARD main fuel line onto main fuel fitting (9). Tighten the line to a torque of 13 N m (10 lb ft).
If a visual inspection of the fuel line connections and the coolant line connections is not performed during the ARD ignition test, fuel leaks or coolant leaks may result in a fire hazard which could result in personal injury or death. Visual inspection of the fuel line connections and the coolant line connections is the only method to detect a fuel leak or a coolant leak on the ARD system. Visually inspect the fuel line connections and the coolant line connections at the ARD head and the ARD manifold when the ARD ignition test is active.
Illustration 6 g02016674
Perform a test for ARD ignition. Refer to Troubleshooting, "ARD Ignition - Test". Refer to Illustration 6.Note: The "ARD Ignition - Test" can be successful even if a fuel leak is present. The ARD ignition test pressurizes the main fuel line and pilot fuel line with pressure in order to help assist with detecting a leak. Visually inspect all fuel line connections for a leak during the test for the ARD ignition. Visual inspection is the only method in order to detect a fuel leak on the ARD system.Note: Also, check the fuel connections at the ARD fuel manifold and the connections for the coolant at the ARD combustion head for any possible leaks.