0386070 JOHNSON CYLINDER AND C'CASE ASSY

Table 1
Required Tools
Tool Part Number Part Description Qty
A 342-9516 Line Socket 1
B - Loctite C5A Copper Anti-Seize -
C 195-4609 Seal Pick 1
D - Isopropyl Alcohol -
E 5P-4996 Plug 2-
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Turn the fuel supply to the OFF position and turn the power disconnect switch to the OFF.
Illustration 1 g03617951
Open door (1) and remove cover (2).
Illustration 2 g03617959
Remove bolt (11). Note: Cap all tube assemblies and fittings that are disconnected in order to prevent fluid loss and keep contaminants out of the systems.
Disconnect tube assembly (7) and hose assemblies (3), (4), and (5).
Remove allen bolt (9). Use Tooling (A) in order to disconnect flame detection temperature sensor (10). Disconnect connector assemblies (8) and (6).
Remove bolts (13) and disconnect tube assembly (14). Remove the gasket (not shown).
Remove exhaust elbow (12). Refer to Disassembly and Assembly Manual, "Flexible Exhaust Pipe - Remove and Install" for the correct removal and installation procedure.
Illustration 3 g03618096
Remove nuts (19) and remove combustion head (18).
Remove gasket (17), tube assembly (16), and gasket (15). Note: The gaskets are one time use only. Replace upon installation.
If required, remove studs (20).
Illustration 4 g03618298
Remove fittings (21), (22), (24) and (25).
Remove spark plug (23).
Illustration 5 g03618317
Use Tooling (C) in order to remove O-ring seals (26) and (27) from connector assembly (8). Discard O-ring seals (26) and (27). Installation Procedure
Install combustion head (18) in the reverse order of removal.
Tighten fittings (21) and (22) to a torque of 60 6 N m (44 4 lb ft).
Tighten fittings (24) and (25) to a torque of 30 2 N m (22 1 lb ft).
Tighten spark plug (23) to a torque of 47 4 N m (35 3 lb ft).
Apply Tooling (B) onto the threads of studs (20). Install the studs. Tighten studs (20) to a torque of 17 2 N m (150 18 lb in).
Apply Tooling (B) onto the threads of the studs (20) and nuts (19). Tighten nuts (19) in a crisscross pattern to a torque of 23 3 N m (17 2 lb ft). Tighten nuts (19) again in a crisscross pattern to a torque of 28 3 N m (21 2 lb ft). Tighten nuts (19) again in a crisscross pattern to a torque of 28 3 N m (21 2 lb ft).
Use caution when you are using isopropyl alcohol. Avoid prolonged skin contact with isopropyl alcohol.Vapors may be harmful if inhaled. Use only in a well ventilated area. Do not smoke while using isopropyl alcohol.Isopropyl alcohol is flammable. Do not use near an open flame or near welding operations. Keep isopropyl alcohol away from heated surfaces exceeding 482°C (900°F).
Note: This connection is an electrical connection and cannot be lubricated with a petroleum-based lubricant. Isopropyl alcohol is the only approved lubrication for this connection.
Lubricate new O-ring seals (26) and (27) with Tooling (D) prior to installation.
Apply Tooling (B) to the threads of flame detection temperature sensor (10) and install the sensor. Use Tooling (A) in order to tighten flame detection temperature sensor (10) to a torque of 45 5 N m (33 3 lb ft).
Tighten tube assembly (7) to a torque of 16 2 N m (142 18 lb in).
Tighten hose assembly (5) to a torque of 11 2 N m (97 18 lb in).
Tighten hose assembly (4) to a torque of 16 2 N m (142 18 lb in).
Tighten hose assembly (3) to a torque of 16 2 N m (142 18 lb in).
Check the coolant level. If necessary, refer to Operation and Maintenance Manual, "Coolant - Change" for the proper filling procedures.
Perform the ARD ignition test. Refer to Troubleshooting Manual, "ARD Ignition - Test".