0435358 JOHNSON DECAL SET, 90 models

Start By:a. remove muffler supportb. remove fuel injection nozzlesc. remove inlet manifoldd. remove exhaust manifolde. remove thermostat housingf. remove rocker shaft and push rods 1. Remove evenly and gradually twenty-two head bolts (1) in reverse of the sequence illustrated in C53860P1. Lubricate the threads and the thrust faces of the bolts with engine oil before assembly. When installing cylinder head, to tighten the bolts evenly and gradually in number sequence to 110 N m (80 ft lb). Repeat this process once again of tightening the bolts evenly and gradually in number sequence to 110 N m (80 lb ft). Then, use Tool (A) tighten all bolts and nuts in number sequence as follows: a. Short bolts (s) 150° further (2.5 flats)b. Medium length bolts (m) 180° further (3.0 flats)c. Long bolts (L) 210° further (3.5 flats) 2. Attach chains and a suitable lifting device to cylinder head (2) as shown. Lift the cylinder head straight up and off the engine block. The weight of the cylinder head is 41 kg (90 lb).
Do not use a pry bar to separate the cylinder head from the cylinder block.
Place the cylinder head on a surface that will not damage the cylinder head face.
3. Remove cylinder head gasket (3). Do not use any sealant or gasket compound on the cylinder head gasket. When installing the cylinder head gasket be sure the gasket is stamped "FRONT TOP" for correct installation. When installing the gasket and the cylinder head, place Tool (B) in positions 15 and 20 as numbered on C53860P1. For installation of the cylinder head, reverse the removal steps. Refer to Specification Manual SENR5541, for additional information on tightening the cylinder head bolts to correct torque. Refer to Systems Operation Testing & Adjusting Manual SENR5542 for topic "Cylinder Compression" for cylinder head check using Tool Group 9U6274.End By:a. install rocker shaft and push rodsb. install thermostat housingc. install exhaust manifoldd. install inlet manifolde. install fuel injection nozzlesf. install muffler supportDisassemble & Assemble Cylinder Head
Start By:a. remove cylinder head Before beginning Disassembly & Assembly of the cylinder head, refer to Systems Operation & Testing & Adjusting Module, SENR5542 for the procedure, "Valve Depth Check" and other pertinent information on the cylinder head. 1. Mark or identify the valve location on the bottom of the cylinder head if the valves are to be used again.2. Place cylinder head on Tool (A) as shown.3. Use Tool (B) to compress the valve spring.
Be sure the valve springs are compressed squarely so the valve stem is not damaged.
4. Remove two collets (1). Slowly release pressure on Tool (B). Remove Tool (B). 5. Remove spring cap (2). Remove valve springs (3). 6. Remove valve (4) out of the bottom of the cylinder head as shown. 7. Remove valve seal (5) and seat washer (6). 8. Turn cylinder head over and reposition Tool (A).9. Install Tool (C) as shown. Remove valve seat (7). While expanding Tool (C), rotate the tool enough to clean the carbon deposits from under the valve seats to create a good grip on the valve seat. 10. Install Tool (D) as shown. Remove valve guide (8) (not shown). The following steps are for the assembly of the cylinder head. 11. Use Tool (F) to install valve seat (7).12. Turn cylinder head over and reposition on Tool (A). 13. Install valve guide (8) with Tool (D) and Tool (E) as shown. Clean out the cylinder head bore that the guide will be positioned in. Lubricate the guide with clean engine oil. Install the valve guide with the smaller diameter for the later installation of the valve seal facing the top of the cylinder head. The exhaust valve guide has a counterbore at the bottom and is slightly longer than the inlet valve guide. Refer to Specifications Module SENR5541 for more information on the valve guides. 14. Install seat washer (6) and valve seal (5). 15. Install valve (4) from bottom of cylinder head as shown. Lubricate the valve with clean engine oil before inserting into the cylinder head guide. 16. Install valve springs (3) and spring cap (2). 17. Use Tool (B) to compress the valve springs.18. Install two collets (1). Slowly release pressure on Tool (B). Remove Tool (B).End By:a. install cylinder head