0382385 JOHNSON THERMOSTAT ASSY., Cyl. head

INJECTION NOZZLE (Right side illustrated)
1. Lines (eight, four each side). 2. Injection nozzles (eight, four each side). 3. Clamps (eight, four each side).1. Remove valve cover, fuel return manifold, and rocker arm assembly.2. Remove the fuel injection nozzle clamp (3).3. Disconnect the fuel injection nozzle (2) and the fuel injection line (1) from the adapter.4. Remove the adapter (4) and lift injection nozzle (2) out of the cylinder head.
ADAPTER AND NOZZLE REMOVAL
2. Injection nozzle. 4. Adapter. 5. O-ring seal. 6. O-ring seal.
Pull nozzle straight out, by hand, to remove. Slight twisting action is permissible if necessary. Never pry out a nozzle with a screwdriver or other similar tool.
Always replace O-ring seals (5) and (6) before installing nozzle.5. Use needle-nose pliers to remove carbon seal dam (8). Always install a new compression seal (7) and carbon seal dam (8) before installing injection nozzle.
REMOVING CARBON SEAL DAM
7. Compression seal. 8. Carbon seal dam.Install Fuel Injection Nozzles
1. Be sure the bore in the cylinder head and fuel inlet fittings are clean.
Never install an injection nozzle that has been dropped, without first testing it with the 8S2242 Nozzle Tester Group. The injector tips are very hard and brittle and break easily.
2. Install a new compression seal and carbon seal dam. Use an 8S2252 Carbon Seal Dam Installation Tool (9) to install the carbon seal dam.
INSTALLING CARBON SEAL DAM
9. 8S2252 Carbon Seal Dam Installation Tool.3. Install a new O-ring seal (6) on the injection nozzle (2) and a new O-ring seal (5) on the adapter (4).4. Install the injection nozzle (2) into the cylinder head using a twisting motion. Do not use lubricant in the cylinder head bore or on the nozzle body.
INSTALLING NOZZLE
2. Injection nozzle. 4. Adapter. 5. O-ring seal. 6. O-ring seal.
Do not bend the injector inlet connection when installing injector into cylinder head. Bending of the inlet connection creates tension on the injector and causes binding of the needle in the guide.
5. Install the adapter (4) and tighten the injection nozzle-to-adapter retaining nut. Tighten retaining nut to 30 5 lb. ft. (4.1 0.7 mkg). Hand tighten the fuel injection line.6. Install the injection nozzle clamp.7. Install the fuel return manifold and rocker arm assembly. Install retaining bolts and locks. Tighten bolts to 18 5 lb. ft. (2.5 0.7 mkg) and bend locks.8. Adjust the intake valve clearance to .015 in. (0.38 mm) and the exhaust valve clearance to .025 in. (0.64 mm).9. Install valve cover. Install mounting bolts and tighten to 120 24 lb. in. (138 28 cm.kg).10. Purge the fuel lines of air by motoring the engine until fuel, free of air, flows from the connections.11. Tighten the fuel line connections to 30 5 lb. ft. (4.1 0.7 mkg).12. Start the engine and correct any fuel leaks that may occur.Disassemble Fuel Injection Nozzle (9L9263 Nozzles)
Do not disassemble the nozzle unless testing indicates that servicing is necessary. See the TESTING AND ADJUSTING section of the Service Manual. Do not clean or readjust a nozzle that has excessive return leakage. Excessive return leakage is a sign of impending major nozzle failure that cannot be corrected by cleaning or adjusting and can possibly result in serious engine damage.
Use extreme care in keeping the work area and tools clean. Handle all parts with care to avoid any damage.
1. Place the nozzle in the holding tool (2) and secure the tool in a vise. Do not clamp any part of the nozzle body directly in the vise.2. Loosen pressure adjusting screw locknut (1).3. Holding the nozzle in one hand, invert it and back out the pressure adjusting screw allowing the spring, spring seats and ball washer to fall into your hand. The valve may slide out, by its own weight, and should be handled carefully by its stem.
REMOVING LOCKNUT (Typical Example)
1. Locknut. 2. 8S2250 Nozzle Holding Tool.
LOCKNUT REMOVED (Typical Example)4. If the valve does not fall out, remove it with retractor (3). To prevent bending the valve, bottom it in the body with the retractor. Push down on the retractor body to mount the collet. Turn the knurled nut counterclockwise to secure the collet and withdraw the valve.
REMOVING VALVE
3. 8S2254 Valve Retractor.5. Place the parts in solvent to loosen carbon and deposits of foreign material. Do not soak the body assembly in solvent for over 1 to 2 hours. The solvent can damage the epoxy bond used to secure the body assembly components together.Assemble Fuel Injection Nozzle (9L9263 Nozzles)
Before assembly, wash all parts thoroughly. Flush the body to remove any debris or lapping compound. Assemble while all parts are wet with clean fuel.1. Handle valve (1) by its shank and slide it partially into the body.2. Assemble ball washer (5), spring upper seat (4), spring (3) and spring lower seat (2) to the lift and pressure adjusting screw assembly (6).3. Tilt the nozzle body and with spring lower seat (2) in contact with the top of valve (1), as illustrated, push the valve and spring components into the body.
Be careful not to dislodge spring lower seat (2) during assembly.
ASSEMBLING NOZZLE (Typical Example)
1. Valve. 2. Spring lower seat. 3. Spring. 4. Spring upper seat. 5. Ball washer. 6. Lift and pressure adjusting screw assembly.4. Tighten the adjusting screw assembly (6) by hand until the spring compresses with enough force to hold all the parts in place (8 to 10 turns).5. Adjust valve lift, opening pressure and tighten the locknut. See covering topics.Service And Inspect Fuel Injection Nozzle (9L9263 Nozzles)
1. Use the brush (4) to clean the tip and body exterior.2. Secure the 8S2247 Cleaning Wire [.008 to .009 in. (0.20 to 0.23 mm) dia.] in pin vise (1) with 1/32 in. (0.79 mm) to 1/16 in. (1.59 mm) of wire protruding. A longer length of wire can bottom in the sac hole and break off in the orifice. Remove any burrs from the wire tip with the 8S2260 Stone. Stoning a flat surface on one side of the wire helps in reaming carbon from a clogged orifice.Insert