5036494 JOHNSON *CAP, RUBBER

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
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.
Reference: 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 hose.
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 g01062281
Install the correct cylinder head gasket (19) and the new O-ring seals 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.
Attach a suitable lifting device to cylinder head (18). The weight of cylinder head (18) is approximately 135 kg (300 lb). Install cylinder head (18) on the cylinder block. Ensure that all wires, lines, and hoses are free from the cylinder head.
Illustration 2 g01062278
Install the gasket on cylinder head (18) .
Install new cylinder head bolts (17). 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 12 for the correct tightening procedure.
Illustration 3 g00517501
Tightening SequenceNote: 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).
Install the head bolt spacers on the three head bolt studs. Tighten the head bolt spacers to a torque of 100 20 N m (75 15 lb ft).
Illustration 4 g01062276
Install water outlet manifold (16) and bolts (15) .
Illustration 5 g01062275
Hold tube assembly (14) in position and connect fittings (12). Install bolts (13) .
Illustration 6 g01062274
Connect harness assembly (11). Tighten bolt (10) to a torque of 6 1 N m (53 9 lb in).