5001036 JOHNSON THERMOSTAT ASSY.

Table 1
Required Tools
Tool Part Number Part Description Qty
B 298-5564 T40 Torx Socket 1
D 1U-5718 Vacuum Pump 1
169-7372 Fluid Sampling Bottle 1
4C-4057 Tube
7.9 mm (0.31 inch) Outside Diameter 1
E 276-1216 Injector Pipe Nut Tool 1
F 247-5377 Torque Wrench 1
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct training.Before begining 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 Systems Operation, Testing and Adjusting Manual, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
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.
Use a deep socket in order to remove the electrical connections from the electronic unit injectors. Use of incorrect tooling will result in damage to the electronic unit injectors.
Illustration 1 g01341874
Typical Injector Code
If a replacement electronic unit injector is installed, the correct injector code must be programmed into the electronic control module. Refer to Troubleshooting, "Injector Code - Calibrate" for more information. The code that is required to obtain the injector code is located at Position (X). Note: Record the Injector Code (X) before the electronic unit injector is installed.
Use Tooling (D) in order to remove any fuel from the cylinder. Note: Evacuate as much fuel as possible from the cylinder before installing the electronic unit injector.
Ensure that the fuel inlet port of the electronic unit injector is capped. Ensure that the electronic unit injector is clean.
Illustration 2 g01255701
On installing an original electronic unit injector, install a new O-ring seal (15) and sealing washer (14) to electronic unit injector (11). Ensure that the O-ring seal (15) and sealing washer (14) on a new electronic unit injector are not damaged and in place.Note: Do not lubricate the O-ring seal.
Ensure that the seat for the electronic unit injector in the cylinder head is clean and free from damage. Ensure that the sealing washer has been removed from the cylinder head.
Illustration 3 g01255699
The rocker shaft is not shown for clarity.
Position clamp (13) between the rocker arm and the valve springs. Align electronic unit injector (11) to the bore for the electronic unit injector in the cylinder head. Install the clamp to the electronic unit injector. Ensure that the electronic unit injector is pushed firmly against the seat in the cylinder head.
Install a new torx screw (12) to clamp (13). Tighten the torx screw finger tight.
Remove the cap from electronic unit injector (11). Install a new seal (8) to electronic unit injector (11) and to the valve mechanism cover base. Ensure that the flange on the seal is flush with the valve mechanism cover base.
Remove the plugs from the new fuel injection line. Loosely install the fuel injection line. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure. Note: Ensure that the ends of the fuel injection line are seated in the electronic unit injector and the fuel manifold. Tighten the nuts finger tight.
Use Tooling (B) to tighten torx screw (12) to a torque of 27 N m (20 lb ft). Note: Tooling (B) must be used to ensure no damage to the rocker arms.
Use Tooling (E) to tighten the fuel injection line to a torque of 30 N m (22 lb ft). Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure.
Illustration 4 g01416992
Typical example
Install valve bridges (5) (not shown) to the cylinder head. Note: Ensure that used valve bridges are reinstalled in the original location and the original orientation. Do not interchange the location or the orientation of used valve bridges.
Illustration 5 g01355048
The correct location of val