5032760 JOHNSON BOLT (8X30mm)

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     9U-6238     Guide Bolt     2    
B     8T-3052     Degree Wheel     1    
Thoroughly clean the top of the cylinder block and the bottom of the cylinder head. Ensure that there is no debris in the cylinder bores.
Illustration 1 g00753300
Place cylinder head gasket (5) on dowels (4) on top of the cylinder block. The cylinder head gasket (5) is stamped "FRONT TOP". Do not use any sealant or compound on the cylinder head gasket.
Illustration 2 g00633611
Install Tool (A) in positions 15 and 20 in the cylinder block. Refer to Illustration 4.
Illustration 3 g00753281
Attach a suitable lifting device to cylinder head (3) .
Place cylinder head (3) on the cylinder block. Ensure that the cylinder head is positioned on dowels (4) and that cylinder head gasket (5) is positioned correctly.
Remove Tool (A) .
Lubricate cylinder head bolts with clean engine oil.
Illustration 4 g00568739
Gradually tighten all of the bolts (1 through 32) in a numerical sequence to a torque of 110 N m (80 lb ft).
Tighten all of the bolts (1 through 32) again in a numerical sequence to a torque of 110 N m (80 lb ft).
Place an index mark on the bolts and use Tool (B) in order to further tighten the bolts. Refer to Illustration 4.
Turn the short bolts that are marked with an "S" for an additional 150 degrees (2.5 flats).
Turn the bolts (medium length) that are marked with an "M" for an additional 180 degrees (3.0 flats).
Turn the long bolts that are marked with an "L" for an additional 210 degrees (3.5 flats).
Install the electrical connection for the fuel shutoff solenoid. Install the electrical connection for the water temperature sender. Install the electrical connection for the water temperature switch.
Illustration 5 g00740971
For naturally aspirated engines, install line (1) that connects the crankcase breather to the air intake housing.End By:
Install the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install".
Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".
Install the engine crankcase breather. Refer to Disassembly and Assembly, "Crankcase Breather - Remove and Install".
Install the expansion tank. Refer to Disassembly and Assembly, "Expansion Tank - Remove and Install".
Install the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install".
Install the fuel injection nozzles. Refer to Disassembly and Assembly, "Fuel Injection Nozzles - Install".
Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install".
Install the inlet and exhaust manifold. Refer to Disassembly and Assembly, "Inlet and Exhaust Manifold - Remove and Install".
Install the aftercooler, if equipped. Refer to Disassembly and Assembly, "Aftercooler - Install".
Install the turbocharger, if equipped. Refer to Disassembly and Assembly, "Turbocharger - Install".
Fill the coolant system. If the engine uses extended life coolant, refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change". If the engine uses diesel engine antifreeze/coolant, refer to Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change".
Connect the electrical connections at the battery.