0388936 JOHNSON CARBURETOR ASSEMBLY

Table 1
Required Tools
Tooling Part Number Description Qty
A 8S-9906 Ratchet Puller 1
B 5P-3931 Anti-Seize Compound 1 Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.
Clean the machined surfaces of the cylinder head and cylinder block that make contact with the cylinder head gasket.
Illustration 1 g01002751
Install new cylinder head gasket (1) on the cylinder block. Ensure that the holes in the cylinder head gasket are in alignment with the holes in the cylinder block.
Attach a suitable lifting device and suitable lifting chains to the cylinder head assembly. Attach Tooling (A) to the bracket and the lifting device. The weight of the cylinder head assembly is approximately 230 kg (510 lb).
Place the cylinder head assembly in position on the cylinder block.
Illustration 2 g01002752
Apply Tooling (B) on the threads of cylinder head bolts (3). Loosely install the cylinder head bolts and washers.
Install pushrods (4). Place rocker shaft (2) in position on the cylinder head.
Illustration 3 g01002753
Illustration 4 g01002756Note: Ensure that the dowels in the rocker shaft assembly are in alignment with the holes in the cylinder head before you install the bolts.
Apply Tooling (B) on the threads of the rocker shaft bolts and install the rocker shaft bolts and washers. Tighten the cylinder head and rocker shaft as follows:
Tighten all the bolts in the number sequence to a torque of 155 N m (115 lb ft).
Tighten all the bolts in the number sequence to a torque of 250 17 N m (185 13 lb ft).
Tighten all the bolts in the number sequence to a torque of 250 17 N m (185 13 lb ft). After the engine is warm, the minimum amount of torque for the bolts is 205 N m (150 lb ft).
Tighten all the bolts in the letter sequence to a torque of 30 N m (22 lb ft).
Tighten all the bolts in the letter sequence to a torque of 43 7 N m (32 5 lb ft).
Tighten all the bolts in the letter sequence to a torque of 43 7 N m (32 5 lb ft). The minimum amount of torque on the bolts must be 37 N m (27 lb ft) after the engine is warm.
Make adjustments until the intake valve clearance is 0.38 mm (0.015 inch) and the exhaust valve clearance is 0.76 mm (0.030 inch). Reference: For additional information about the valve clearance, refer to Testing and Adjusting, "Valve Clearance Setting" for the engine that is being serviced.
Connect the covers to the adapters and spark plugs.
Illustration 5 g01002759
Install the turbocharger drain line (6) and oil supply line (5).
Illustration 6 g01002767
Connect harness assembly (8) to the magneto. Connect each wire to the original terminal. Install clip (7) on the engine block.
Illustration 7 g01002768
Install water pump elbow (11) and tighten the clamp on the hose to the oil cooler.
Install tube assembly (9) from the aftercooler.
Install tube assembly (10).
Illustration 8 g01002771
Connect tube assembly (14) to the engine oil cooler.
Install tube assembly (12).
Connect control rod (13) to the lever.
Fill the cooling system with coolant to the correct level. Reference: For additional information about the cooling system, refer to Service Manual, SEBR0513, "Cooling System" for the engine that is being serviced.End By:
Install the valve cover. Refer to Disassembly and Assembly, "Valve Cover - Remove and Install" for the engine that is being serviced.