90011-ZZ3-000 Honda BOLT, HEAD COVER

General Information
A separate parts list and drawing is included for each group. In order to minimize the sorting of parts and to ease the installation of these components, it is strongly suggested that SEPARATE parts orders be placed for the parts in EACH group in the conversion. The parts list is for ONE engine except for 106-5344 Conversion Group for the Lower Cover. This group specifies parts specifically for the port and starboard engine. It will be necessary to place TWO separate parts orders for all of the other groups.Repositioning Engine Components
The location of engine components must be carefully reviewed before starting the installation of the conversion arrangement. Inspect the following components closely.1. The position of the turbochargers will require the exhaust piping to be moved rearward 61.9 mm (2.44 in), in order to maintain proper alignment of all the exhaust connections. Determine exactly which connection(s) need(s) to be repositioned to allow the piping to move straight back. Also inspect the exhaust hangers/brackets to make sure that the piping is correctly supported.2. The new watercooled exhaust risers require water elbows and a connector from the bottom rear of each of the exhaust manifolds to the bottom of the risers. If the marine gear mounting brackets are also connected to the sides of the flywheel housing, the mounting brackets may need to be reworked to clear the new elbows and connectors.3. If the marine gear oil cooler is connected to the engine mounted heat exchanger, a brass 90° elbow with 1"-11 1/2 NPTF thread and a barbed end for 19 mm (.75 in) I.D. coolant hose must be added to the right bottom side of the heat exchangers. Verify the I.D. of the hose.Part Number Index
The 106-5328 Conversion Arrangement consists of the following groups. Component Removal
1. Remove the heat exchanger, deaerators, auxiliary raw water pump, temperature regulator housings, brackets, hoses, elbows, clamps, connectors and other parts associated with the heat exchanger. Remove the auxiliary water pump only if it will be replaced. Do not remove the jacket water pump.2. Remove the air cleaner elements, silencers, boots, brackets, and other related parts.3. Remove the fuel lines as left-side and right-side groups.4. Remove the aftercooler air inlet pipes and aftercooler cover. If necessary clean the aftercooler core.5. Remove the heat insulation wrap from the turbochargers and risers.6. Remove the turbocharger's oil/water lines and jacket water lines.7. Remove the turbocharger support brackets, turbochargers, and exhaust risers.8. Remove the rear lifting eye and rework to provide additional clearance.Component Installation
Install the following groups:1. 105-0268 Auxiliary Pump Group (optional)2. 106-5360 Conversion Group (Aftercooler)3. 106-5331 Conversion Group (Valve Cover)4. 4P9219 Air Cleaner Group5. 4P7924 Air Cleaner Mounting Group6. 106-5344 Conversion Group (Lower Cover)7. 106-5369 Conversion Group (Watercooled Exhaust Manifold)8. 4P7473 Turbocharger Group9. 4P7476 Turbocharger Oil Lines Group10. 106-5379 Conversion Group (Turbocharger Water Lines)11. 4P7477 Air Lines Group12. 106-5400 Conversion Group (Heat Exchanger)13. 7E1123 Lifting Eye GroupThe following pages contain the conversion assembly procedures for each group along with a component drawing and parts list.105-0268 Auxiliary Pump Group, Gilkes (Optional)
The 105-0268 Auxiliary Pump Group is optional for this conversion arrangement. This pump group is not required as part of the conversion in order to add the watercooled turbochargers, exhaust risers, heat exchanger and air cleaners.If the optional 105-0268 Auxiliary Pump Group is NOT used, the 4P7987 Hose is not needed (part of 106-5400 Conversion Group). Order one 109-2169 Hose for the Jabsco Auxiliary Water Pump.
105-0268 Auxiliary Pump Group (Gilkes) 106-5360 Conversion Group (Aftercooler)
The 108-3593 Aftercooler Cover Group (1) is serviced as a complete assembly. Install a new gasket (2) and reuse the original bolts and washers to install aftercooler cover. If necessary, clean the aftercooler core.
106-5360 Conversion Group (Aftercooler) 106-5331 Conversion Group (Valve Cover) (Port Engine)
This conversion requires additional parts along with the original parts already on the engine. Additionally, one 7C9621 Plug, one 8C5196 Seal and one 6N2758 Rocker Arm Cover are needed. The right rear flat valve cover must be installed on the right rear to clear the bracket for the Air Cleaner Mounting Group. Reuse the original valve cover mounting bolts.Port Engine
Reposition the adapters and plugs in the valve covers as follows.1. Left front cover. Put the new 7C9621 Plug with 8C5196 Seal in the front and a 7C6514 Adapter in the rear of the valve cover. Install the breather onto the adapter.2. Left rear cover. Put 7C9621 Plugs in both locations.3. Right front cover. Put 7C6514 Adapters in both locations. Install oil filler plug onto front adapter and a breather onto the other adapter.4. Right rear cover. Install a 6N2758 Rocker Arm Cover (no holes).
106-5331 Conversion Group (Port Engine)106-5331 Conversion Group (Valve Cover) (Starboard Engine)
Starboard Engine
Reposition adapters and plugs in the valve covers as follows.1. Left front cover. Put 7C6514 Adapters in both locations. Install oil filler plug on front adapter and a breather on the other adapter.2. Left rear cover. Put 7C9621 Plugs in both locations.3. Right front cover. Put the new 7C9621 Plug with 8C5196 Seal in the front and a 7C6514 Adapter in the rear of the valve cover. Install a breather on the adapter.4. Right rear cover. Install a 6N2758 Rocker Arm Cover (no holes). Reuse the original valve cover mounting bolts.
106-5331 Conversion Group (Starboard Engine)4P9219 Air Cleaner Group
A length of 5P1505 Hose (11), 185 cm (72.8 in), is used for drain lines from the air cleaners to the oil pan. The hose should be cut to the following lengths. One piece 150 mm (5.9 in) long and one piece 750 mm (29.5 in) long for the right side of the engine. One piece 150 mm (5.9 in) long and 800 mm (31.5 in) long for the left side of the engine.The drain line on the right side of the starboard engine should be connected to the oil level gauge hole. All other connections should be made to the oil pan.One-way check valves (13) are used in the drain lines. Arrows on the check valves must point in a downward direction.
4P9219 Air