0435943 JOHNSON CYL. & C'CASE ASSY.

Start By:a. remove exhaust manifold The exhaust manifolds do not have to be removed unless all the cylinder head assemblies are to be removed.1. Drain the coolant from the cooling system.2. Shut off the fuel supply on the engine. 3. Remove fuel lines (2), thermocouple (1) and the fuel line manifold from the cylinder head assembly. 4. If equipped, disconnect hose assembly (4) from water manifold (3). Remove the bolts to remove a section of water manifold (3) and elbow (6) from the cylinder head assembly.5. Remove bracket (5) from the cylinder head assembly. Air inlet elbow (7) does not have to be removed from the cylinder head assembly, only the bolts that hold the elbow to the cylinder head assembly.6. Remove the bolts, and remove air inlet elbow (7) from the cylinder head assembly. 7. Remove the access cover from under the cylinder head assembly. Remove the bolt and cap (9) to disconnect rod assembly (8) from fuel control shaft (10).8. Remove the rocker shaft assemblies and push rods. See Remove Rocker Shaft Assemblies And Push Rods for this procedure. 9. Remove bolts (14) to remove lever assembly (13) and rod assembly (8) as a unit from the cylinder head assembly. If the lower end of rod assembly (8) does not have enough clearance to be removed, use tool (A) to turn the flywheel until the lower end of rod assembly (8) can be removed between the camshaft and engine block.10. Remove the bolt and clamp (12) from the fuel injector.
Do not put a force on the fuel injection rack or cause damage to it when the injectors are removed.
11. Use a pry bar to loosen fuel injector (11). Remove fuel injector (11) from the cylinder head assembly. 12. Remove the bolts to remove valve cover base (15) and the gasket from the cylinder head assembly. 13. Fasten a hoist to cylinder head assembly (16) with tooling (B). Remove all of bolts (17) and (18) to remove cylinder head assembly (16) from the engine. The weight of the cylinder head assembly is 47 kg (105 lb.). 14. Remove head gasket (19), the seals, the spacer plate and spacer plate gasket from the engine.Install Cylinder Head Assemblies
Thoroughly clean the spacer plate and bottom surface of the cylinder head assembly. A new spacer plate gasket must be installed when the cylinder head assembly is removed.1. Install the spacer plate gasket and spacer plate. See the topic, Install Spacer Plate. 2. Install head gasket (1) on the spacer plate. Do not use any adhesives.
Before installation of the cylinder head assembly make sure the 4D0514 Plug at location (X) is installed.
3. Fasten a hoist to cylinder head assembly (2). Put the cylinder head assembly in position on the spacer plate. 4. Put 5P3931 Anti-Seize Compound on the threads of the cylinder head bolts. Install the cylinder head bolts and washers. Tighten the bolts in the following sequence:a. Tighten all of the bolts to a torque of 30 5 N m (22 4 lb.ft.).b. Tighten bolts 1 through 8 in number sequence to a torque of 270 35 N m (200 26 lb.ft.).c. Tighten bolts 1 through 8 in number sequence to a torque of 450 20 N m (330 15 lb.ft.). 5. Install bolts (4) to hold the cylinder head assembly.6. Make sure the O-ring seals are installed around the two dowels in the bottom of valve cover base (3). Put the gasket and base (3) in position, and install the bolts to hold them to the cylinder head assembly. 7. Make sure the three O-ring seals are installed on fuel injector (5), and put clean engine oil on them and in the bore in the injector.
Do not tap or hit on the injector follower to install the injector. Damage and failure to the injector can be the result.
To prevent a carbon deposit between the injector and the injector bore, make sure the injector body (especially the tapered area) and the injector bore are clean and free of foreign material.
8. Put fuel injector (5) in position. Install the clamp, washer and bolt. Tighten the bolt to push fuel injector (5) all the way in its bore. Tighten the bolt to a torque of 65 7 N m (48 5 lb.ft.).9. Check to make sure the fuel injection rack moves freely by hand in the injector after the injector is installed.10. Install lever assembly (6) and rod assembly (7) as a unit in the cylinder head assembly. If necessary, use tool (B) to turn the flywheel until the camshaft moves enough to permit the lower end of rod assembly (7) to move into position. Make sure lever assembly (6) is engaged correctly with the fuel injection rack, and install the bolts to hold it in position.11. See Testing And Adjusting module for the correct adjustment of the fuel injection control group. 12. Put rod assembly (7) in position on the control shaft, and install the bolt and cap (8) to hold it. 13. Install access cover (9) and the seal under the cylinder head assembly. 14. Put the gaskets and air inlet elbow (10) in position, and install the bolts to hold the air inlet elbow in position. 15. Install bracket (13) on the cylinder head assembly.16. Put the gaskets, water manifold (11) and elbows (14) in position as a unit, and install the bolts. If equipped, connect hose assembly (12) to water manifold (11). 17. Make sure the O-ring seals for the fuel manifold and the lines are installed and have clean engine oil on the seals. Install the fuel manifold and fuel lines (16). Install thermocouple (15).18. Turn on the fuel supply to the engine.19. Fill the cooling system with the coolant to the correct level. See the Maintenance Manual.End By:a. install exhaust manifolds