0436227 EVINRUDE CARB. ASSY., 120-125ESX

START BY:a. tilt cab (24° position) *b. remove air cleaner housingc. remove mufflerd. remove fuel injection nozzlese. remove exhaust manifold*This operation is in the Vehicle Systems Disassembly And Assembly section.1. Fasten a hoist to the hood. Remove four bolts and the clip on the top coolant tube; then remove the hood. Weight is 25 kg (55 lb.). 2. Disconnect hose (1) for the air cleaner indicator and from air inlet elbow (3). Disconnect line (2) for the ether starting aid from air inlet elbow (3).3. Remove air inlet elbow (3) from the cylinder head assembly. 4. Remove tube assembly (4). Loosen hose clamp (5) between the cylinder head assembly and timing gear cover.5. Remove 22 bolts (6) that hold the cylinder head assembly to the cylinder block. Fasten tool (A) and a hoist to the cylinder head assembly. Remove the cylinder head assembly. Weight is 54 kg (120 lb.).Install Cylinder Head Assembly
1. Clean the surfaces of the cylinder head assembly and the cylinder block that make contact with each other. Check the cylinder head and cylinder block deck for flatness. The overall flatness for both the cylinder block and cylinder head should be 0.15 mm (.006 in.) or less. The maximum allowable for any 152.4 mm (6.00 in.) span is 0.08 mm (.003 in.). Make sure the surfaces are clean and dry. Install a new dry gasket on the cylinder block. 2. Inspect the condition of water ferrule and seal (2). Make a replacement if needed. Put water ferrule and seal (2) in position with the adjusting screw of hose clamp (1) toward the top and approximately 45° to the right of vertical as seen from the front of the engine.3. Make sure the seal is installed all the way in the counterbore. If the plugs in the oil passages in the cylinder head were removed, put 5P3413 Pipe Sealant with Teflon on the threads, and install the plugs in the head. 4. Fasten tool (A) and a hoist to the cylinder head assembly. Put cylinder head assembly (3) in position on the cylinder block.5. Put 5P3931 Anti-Seize Compound on all the threads of the head bolts.
Head Bolt Location And Tightening Sequence6. Install the head bolts, and tighten as follows:a. Tighten bolts (1) to (18) by number sequence to a torque of 80 14 N m (60 10 lb.ft.).b. Tighten bolts (1) to (18) by number sequence to a torque of 150 7 N m (110 5 lb.ft.).c. Tighten bolts (1) to (18) again by number sequence to a torque of 150 7 N m (110 5 lb.ft.).d. Tighten bolts (19) to (22) by number sequence to a torque of 43 7 N m (32 lb.ft.). 7. Tighten hose clamp (1).8. Install tube assembly (4). 9. Install the gasket and air inlet elbow (7) on the cylinder head assembly.10. Connect hose (5) for the air cleaner indicator to air inlet elbow (7). Connect line (6) for the ether starting aid to the air inlet elbow.11. Fasten a hoist to the hood, and put the hood in position on the machine. Weight of the hood is 25 kg (55 lb.). Install the four bolts that hold the hood in place. Install the clip on the top coolant tube.END BY:a. install mufflerb. install exhaust manifoldc. install air cleaner housingd. install fuel injection nozzlese. lower cab **This operation is in the Vehicle Systems Disassembly And Assembly section.Disassemble Cylinder Head Assembly
START BY:a. remove cylinder head assembly New cylinder head components are effective with the 943 and 953 Loaders with engine serial numbers 10X2188-2205, 10X2210 and 45V32874. New valve springs, retainers, washers and fuel nozzle clamp assemblies are available as a direct replacement for the former components. All new parts must be used together when a replacement is made of the former parts. It is recommended to change all the retainers, valve springs, fuel nozzle clamp assemblies, washers and spacers on a cylinder head or engine at the same time. Do not mix new and used components on the same cylinder head or engine. 1. Fasten a hoist, and put the cylinder head assembly in position on tool (A). Use adapter plates (1) from tooling (A) to hold the head in place. 2. Put the valves under compression with tool (C).3. Remove the locks from the valves.4. Remove tool (C), retainer, spring, washer and valve from the cylinder head. Put identification marks on the valve as to its location in the cylinder head. 5. There is an earlier and later valve spring used. The earlier spring, a 9N3617, has a 4.877 mm (.1920 in.) wire diameter and an outside coil diameter of 36.6 mm (1.44 in.). The later spring, a 1W4259, has a 5.232 mm (.2059 in.) wire diameter and an outside coil diameter of 39.6 mm (1.56 in.). Check the valve spring force with tool (B). The minimum spring force of a 9N3617 Spring (used) is 191 N (43 lb.) at a length (height) of 42.04 mm (1.655 in.). The spring force of a new 9N3617 Spring is 222 22 N (50 5 lb.). The length (height) is the same as the used spring. The minimum spring force of a used 1W4259 Spring is 187 N (42 lb.) at a length height of 45.8 mm (1.80 in.). The spring force of a new 1W4259 Spring is 216 22 N (49 5 lb.) when the height is the same as above. For additional information, see Guidelines For Reusable Parts - Valve And Valve Springs Specifications, Form No. 8034-03. Also see Guideline For Reusable Parts And Salvage Operation, Form No. SEBF8002.6. Do Steps 2 through 5 for the remainder of the valves. 7. Remove the valve seat inserts with tooling (D).8. Inspect valve guides for wear with tooling (E) or (F). Measure both ends of the valve guide. The diameter of a new valve guide bore is 9.512 .013 mm (.3745 .0005 in.). The maximum permissible diameter is 9.550 mm