0386645 JOHNSON CAP ASSY. COMMUTATOR

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     185-3630     Strap Wrench Assembly     1    
B     1U-5686 (1)     21/32 inch Drill Bit     1    
C     4C-9732 (1)     M16x2.0-D7 Plug Tap     1    
D     9U-5604     M16x2.0 32mm Heli-Coil Insert (2)     1    
E     8T-2799 (1)     Heli-Coil Installation Tool     1    
F     8T-3096     Plug Tap     1    
G     6V-4876     Lubricant     1    
( 1 ) Part of 4C-8367 Thread Repair Kit
( 2 ) This is a special length.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: For more information, refer to Video Tape, LEVN5101, "C-10 and C-12 Head Gasket Repair Procedure".
Thoroughly clean the mating surfaces of the cylinder head and the cylinder block.
Clean all 26 head bolt holes on the cylinder block with Tooling (F) .
After cleaning the threads, remove any debris from the head bolt holes on the cylinder block with a vacuum line.
Visually inspect the head bolt holes on the cylinder block for thread damage.
If a damaged head bolt thread is observed, repair the damaged head bolt thread with a Heli-Coil thread repair kit.
Inspect the cylinder head and the cylinder block for flatness. Refer to Guideline for Reusable Parts and Salvage Operations, SEBF8162, "Procedure to Measure and Salvage Cylinder Head Assemblies and Related Components".
Illustration 1 g00810396
Cylinder Head Gasket (29) Straight Edge
Illustration 2 g00810399
Cylinder Head Gasket (28) Scalloped Edge
Determine the correct cylinder head gasket to use. Refer to Illustration 1 and Illustration 2.
Illustration 3 g00525775
Install the correct cylinder head gasket (26) and new O-ring seals (27) on the cylinder block. Inspect the condition of the remaining gaskets. Replace the gaskets, if necessary.Note: To avoid damage to the cylinder head gasket, use guide bolts of an appropriate size to install the cylinder head.
Use a suitable lifting device to install the cylinder head on the cylinder block.
Illustration 4 g00525534
Install four gaskets (24) on cylinder head (25) .
Install new cylinder head bolts (23). If the engine is equipped with a compression brake, then also install new head bolt studs.
Lubricate the following components with Tooling (G) : the bolt threads, the underside of the bolt heads and the washers. Follow Step 13 for the correct tightening procedure.
Illustration 5 g00517501
Note: Engines that are equipped with a compression brake will have three head bolt studs. Install the head bolt studs in positions (2), (8), and (10). Tighten the head bolt studs in sequence with the cylinder head bolts.
Tighten the cylinder head bolts according to the following procedure:
Tighten bolt (1) through bolt (26) in a numerical sequence to a torque of 160 15 N m (120 11 lb ft).
Tighten bolt (1) through bolt (26) again in a numerical sequence to a torque of 160 15 N m (120 11 lb ft).
Place an index mark on each bolt head. Turn bolt (1) through bolt (26) in a numerical sequence for an additional 90 degrees (1/4 turn).
Loosen bolt (1) through bolt (26) until the washers are loose under the bolt heads.
Tighten bolt (1) through bolt (26) in a numerical sequence to a torque of 160 15 N m (120 11 lb ft).
Tighten bolt (1) through bolt (26) again in a numerical sequence to a torque of 160 15 N m (120 11 lb ft).
Place an index mark on each bolt head. Turn bolt (1) through bolt (26) in a numerical sequence for an additional 90 degrees (1/4 turn).
Tighten bolt (27) through bolt (33) in a numerical sequence to a torque of 28 7 N m (20 5 lb ft).
Illustration 6 g00525468