0435634 JOHNSON DECAL SET, 88 models

8. Disconnect tube (1) from elbow (2).9. Remove the bolts and elbow (2) from the cylinder head. On later machines, there is a wire which must be removed or disconnected.10. Loosen the clamp and disconnect hose (3) from water pump elbow (4).11. Loosen clamps (5). Remove the bolts, water pump elbow (4) and gasket from the water pump. 12. Remove the bolt and disconnect clamp (7) from the cylinder head.13. Remove tube assemblies (6) and (8) from the engine. 14. Remove the bolt and disconnect clip (10) from the cylinder head.15. Remove the bolt from the lifting bracket and disconnect wire harness (9). Install the bolt on the lifting bracket. 9. Fasten a hoist to cylinder head (11). Remove the bolts and cylinder head (11) from the engine. The weight of the cylinder head is approximately 61 kg (135 lb.).
Do not put the cylinder head down on a flat surface. This can cause damage to the fuel injection valves.
The following steps are for the installation of the cylinder head assembly. Always install a new gasket between the spacer plate and cylinder block before the cylinder head is installed. See the topic, Remove Spacer Plate. 10. Thoroughly clean the spacer plate and bottom surface of the cylinder head. Install a new head gasket, water ferrules (12) and the O-ring seal on the hollow dowel.11. Install a new gasket on the water inlet elbow.12. Fasten a hoist to cylinder head and put it in position on the cylinder block. Make sure the cylinder head is in alignment with the dowels in the cylinder block.13. Put 2P2506 Thread Lubricant on all the head bolts and rocker shaft bolts. Install the head bolts and washer that hold the cylinder head in place but do not tighten at this time.14. Remove the bolt from the lifting bracket and connect wire harness (9) to it. Install the bolt on the lifting bracket.15. Connect clip (10) to the cylinder head.16. Install tube assemblies (6) and (8) to the engine as shown.17. Connect clip (7) to the cylinder head.18. Install the gaskets and water pump elbow (4) to the engine. Make sure to tighten the hose clamps.19. Connect hose (3) and tighten the clamp. On later machines, there is a wire which must be installed or connected.20. Install the elbow to the cylinder head and connect the tube to the elbow. 21. Install push rods (14) and rocker shaft (13). Install the bolts and washers. 22. Tighten the bolts as follows:a. Tighten the bolts 1 through 18 in number sequence to a torque of 155 N m (115 lb.ft.).b. Tighten bolts 1 through 18 again in number sequence to a torque of 250 17 N m (185 13 lb.ft.).c. Tighten bolts 1 through 18 again in number sequence (hand tighten only) to a torque of 250 17 N m (185 13 lb.ft.).d. Tighten bolts A through E in letter sequence to a torque of 43 7 N m (32 5 lb.ft.).23. Make an adjustment until the intake valve clearance is 0.38 mm (.015 in.) for the intake and 0.64 mm (.025 in.) for the exhaust. See the topic, Valve Clearance in the Testing And Adjusting Section.24. Install fan drive.25. Install water temperature regulator.26. Install exhaust manifold.27. Install fuel priming pump and primary filter group.28. Install air cleaner group.29. Install the muffler.