0435643 EVINRUDE DECAL SET, Johnson

START BY:a) remove valve cover basesb) remove rocker shaft assemblies and push rodsc) remove water temperature regulator housingsd) remove exhaust manifold 1. Remove 3/8" bolts (1), the support and the brackets from the cylinder block.2. Disconnect wires (2) from the cylinder head asembly. 3. Remove all of the cylinder head bolts (3) except for cylinder head bolt (4). Clean all debris or foreign material from the "V" of the engine before removal of the cylinder heads.
Do not put the cylinder head down on a flat surface. This can cause damage to the fuel injection valves.
4. Fasten tool (A) and a hoist on cylinder head assembly (5). Remove bolt (4), cylinder head assembly (5) and the gasket from the spacer plate. The weight of the cylinder head assembly is 113 kg (250 lb.). A new spacer plate gasket and seals must be installed when the cylinder head assembly is removed. See Remove And Install Spacer Plate.Install Cylinder Head Assemblies
Make sure a new spacer plate gasket has been installed between the spacer plate and cylinder block. See Remove And Install Spacer Plate. 1. Thoroughly clean the spacer plate and the bottom surface of the cylinder head. Install a new gasket (1) as shown. Do not use any adhesives. 2. Fasten tool (A) and a hoist on cylinder head assembly (2) and put it in position on the spacer plate. Make sure the cylinder head is in alignment with dowels (3). 3. Put clean engine oil on the threads of the bolts that hold the cylinder head assembly in position. Install the bolts and washers and tighten them to the correct torque as follows:a) Tighten bolts 1 through 14 in number sequence to a torque of 271 27 N m (200 20 lb.ft.).b) Tighten bolts 1 through 14 in number sequence to a torque of 447 20 N m (330 15 lb.ft.).c) Tighten bolts 1 through 14 again in number sequence to a torque of 447 20 N m (330 15 lb.ft.).d) Install the rocker shaft assembly and push rods. See Install Rocker Shaft Assemblies And Push Rods.e) Tighten bolts 15 through 18 in number sequence to a torque of 271 27 N m (200 20 lb.ft.).f) Tighten bolts 15 through 18 in number sequence to a torque of 447 20 N m (330 15 lb.ft.).g) Tighten bolts 15 through 18 again in number sequence to a torque of 447 20 N m (330 15 lb.ft.). 4. Install bolts (4) that hold the support to the cylinder head assembly finger tight only.5. Install the bolt that holds the support to the timing gear housing, and tighten it to a torque of 43 7 N m (32 5 lb.ft.).6. Tighten bolts (4) to a torque of 43 7 N m (32 5 lb.ft.).7. Put bracket (5) in position as shown, and install bolt (6) that holds the bracket to the cylinder head assembly finger tight only.8. Install the bolt that holds the bracket to the fuel pump group, and tighten the bolt to a torque of 43 7 N m (32 5 lb.ft.).9. Tighten bolt (6) to a torque of 43 7 N m (32 5 lb.ft.).10. Tighten the remaining 3/8" bolts to a torque of 43 7 N m (32 5 lb.ft.).11. Connect the wires to the cylinder head assembly.12. If the studs for the exhaust manifold had to be replaced, install them in the cylinder head assembly, and tighten them to a torque of 25 4 N m (20 3 lb.ft.).13. Make correct rocker shaft and valve adjustments. See Install Rocker Shaft Assemblies And Push Rods.END BY:a) install exhaust manifoldsb) install water temperature regulator housingsc) install valve cover bases