0383662 JOHNSON CARBURETOR BODY, PLUG & THROTTLE VALVE

1. Disconnect bracket (1) from the cylinder block and clamp (3) from the bracket and remove breather tube (2) from the engine. 2. Remove the bolts. Slide adapter assembly (5) into pipe (6).3. Remove tube (7) from pipe (6) and the cover.4. Remove the bolts and plate (4) from the cylinder head and the timing gear cover. 5. Remove tube (8) from the expansion tank and elbow (9).6. Remove the bolts and elbow (9) from the aftercooler. 7. Remove bolt (11) and disconnect clip (10).8. Install bolt (11) back in the hole that holds the lifting bracket. 9. Remove the bolts and elbow (12) from the aftercooler. 10. Remove bolt (14) and disconnect clips (13) that hold the fuel lines to the cylinder head. 11. Remove bolts (15) and (17) and bracket assembly (16) from the cylinder head and air cleaner housing.12. Install bolts (17) back in the holes that hold the lifting bracket. 13. Fasten tooling (A) and a hoist to cylinder head (18). Remove bolts (19) and cylinder head (18) from the spacer plate. The weight of the cylinder head is 222 kg (490 lb.).
Do not put the cylinder head down on a flat surface. This can cause damage to the fuel injection valves.
14. Remove seals (20) and cylinder head gasket (21) from the spacer plate.Install Cylinder Head Assembly
Be sure a new gasket has been installed between the spacer plate and the cylinder block. See REMOVE AND INSTALL SPACER PLATE.1. Make sure all gasket surfaces are clean and free of dirt. 2. Install a new head gasket (2) on the spacer plate and seals (1) on the dowels. 3. Fasten tooling (A) to cylinder head (3) and put it in position on the spacer plate.4. Put clean engine oil on the threads of the cylinder head bolts. Insall the cylinder head bolts and washers. Tighten the bolts in sequence shown in illustration A87019x1:a) Tighten bolts 1 through 20 in number sequence to a torque of 270 25 N m (200 20 lb.ft.).b) Tighten bolts 1 through 20 in number sequence to a torque of 450 20 N m (330 15 lb.ft.).c) Tighten bolts 1 through 20 in number sequence to a torque of 450 20 N m (330 15 lb.ft.) by hand.d) Install rocker shafts and push rods. See INSTALL ROCKER SHAFTS AND PUSH RODS.e) Tighten bolts 21 through 26 in number sequence to a torque of 270 25 N m (200 20 lb.ft.).f) Tighten bolts 21 through 26 in number sequence to a torque of 450 20 N m (330 15 lb.ft.).g) Tighten bolts 21 through 26 in number sequence to a torque of 450 20 N m (330 15 lb.ft.) by hand.h) Tighten the 3/8" bolts to a torque of 43 7 N m (32 5 lb.ft.).5. Make an adjustment to the valves to have a clearance of 0.38 mm (.015) for intake and 0.76 mm (.030) for exhaust. Install the valve cover bases and the inner fuel lines. Tighten the locknuts for the valve adjustment screws to a torque of 28 4 N m (22 3 lb.ft.). 6. Remove bolt (5) from the cylinder head.7. Connect clip (4) to the cylinder head with bolt (5). 8. Install the gasket and elbow (7) to the aftercooler.9. Install tube (6) to the expansion tank and elbow (7). 10. Remove bolts (8) from the cylinder head. 11. Install bracket assembly (9) with bolts (8) and (10). 12. Connect clips (11) and (12) to the cylinder head. 13. Install the gasket and tube (13) to the aftercooler. 14. Install plate (14) on the cylinder head.15. Slide adapter (16) out of the pipe and install the gasket and connect adapter (16) to the cover assembly.16. Install tube (15) to the pipe and the cover. 17. Install breather tube (18) on the engine with bracket (17) and clamp (19).
Do not cause damage to the seals on inner fuel lines (20).
18. Use tooling (B) and install inner fuel lines (20). Tighten the fuel lines to a torque of 40 7 N m (30 5 lb.ft.).END BY:a) install valve cover basesb) install fuel linesc) install fuel filtersd) install turbochargere) install instrument panel