2004 Johnson 60-70HP Fuel Injector Removal and Installation
REMOVAL
WARNING: The components after the high-pressure fuel pump remain pressurized at all times. To protect against fuel spray, relieve fuel line pressure before disconnecting or removing components.
- Remove the port side cover.
- Loosen the clamp and place a large cloth over the end of the fuel feed hose. Slowly pull the fuel feed hose from the fuel delivery pipe. Drain any excess fuel in the hose into a small container.
- Disconnect the four fuel injector connectors.
- Remove the two bolts and the fuel delivery pipe (with the fuel injectors).
CAUTION: A small amount of fuel may be released when the fuel injector is removed from the delivery pipe. Place a shop cloth under the fuel injector before removal to absorb any fuel released. Dispose of the fuel-soaked cloth in an appropriate container.
- Remove each injector from the delivery pipe.
INSTALLATION
Installation is the reverse order of removal with special attention to the following steps.
CAUTION: Do not reuse the O-ring and the cushion once removed. Always use new parts.
- Replace the injector O-ring with a new one using care not to damage it. Install the grommet to the injector.
- Apply a thin coat of fuel to the injector O-ring, then install the injectors into the delivery pipe.
- Replace the injector cushion with a new one and install it on the cylinder head.
- Install the delivery pipe (with the injectors) into the cylinder head.
- Tighten the two delivery pipe bolts and make sure that the injectors rotate smoothly.
- Fuel delivery pipe bolt torque: 23 Nm (2.3 kg-m; 16.5 lb-ft)
- Reconnect the fuel feed hose to the fuel delivery pipe.
- Connect the lead wires to each injector connector.
- Turn the ignition switch "ON" for 3 seconds (to operate the fuel pump), then turn it "OFF". Repeat this (ON and OFF) procedure 3 or 4 times to pressurize the fuel system. Check for fuel leaks around the fuel injector.
