5036688 JOHNSON *DECAL, "BRP" Logo

Illustration 1 g01193067 (1) Assembled height of rocker arm support dowels ... 8.0 1.0 mm (0.32 0.04 inch) (2) Inside diameter of assembled valve guides ... 16.031 0.028 mm (0.6311 0.0011 inch) (3) Assembled height of valve guides ... 20.0 2.0 mm (0.79 0.08 inch) (4) Assembled height of bridge dowels ... 105.0 2.0 mm (4.13 0.08 inch) (5) 1W-1749 Spring (inner spring) Length under test force ... 79.3 mm (3.12 inch)Test force ... 361 36 N (80 8 lb)Free length after test ... 107.0 mm (4.21 inch)Outside diameter ... 47.9 mm (1.89 inch) (6) 1W-1748 Spring (outer spring) Length under test force ... 84.9 mm (3.34 inch)Test force ... 758 76 N (170 17 lb)Free length after test ... 114.0 mm (4.49 inch)Outside diameter ... 68.0 mm (2.68 inch) (7) Procedure to tighten the cylinder head nuts
Lubricate the washer face and the stud threads with 5P-3931 Anti-Seize Compound.
Assemble the cylinder head, the seals, the gasket and the washers. Tighten the nuts by hand.
Simultaneously tension each pair of the studs with either of the following tensioners: 207-5034 Stud Tensioner Tool Gp ... 40000 1520 kPa (5800 220 psi) 191-5320 Stud Tensioner Tool Gp ... 125000 4920 kPa (18130 715 psi)Tighten the nuts by hand. Slowly release the pressure.
Repeat Step 3. (8) Torque for pressure relief plug ... 275 25 N m (200 18 lb ft) (9) Thickness of combustion gasket ... 4.20 0.05 mm (0.160 0.004 inch)Surfaces must be parallel within the following dimension. ... 0.03 mm (0.001 inch) (10) Angle of valve face Angle of the inlet valve face ... 20.25 0.10 degreesAngle of the exhaust valve face ... 30.25 0.10 degrees
Illustration 2 g00290111
Inlet And Exhaust Valves
(11) Depth of bore for new valve seat insert ... 24.00 0.15 mm (0.945 0.006 inch) (12) Valve stem Coat the inlet valve stems and the exhaust valve stems with 8T-2998 Lubricant prior to installation in the cylinder head. Minimum diameter of valve stem ... 15.629 mm (0.6153 inch)Install the valve guide into the cylinder head. The bore in the new valve guide is the following dimension. ... 16.031 0.028 mm (0.6311 0.0011 inch) (13) Diameter of valve seat inserts ... 97.195 0.015 mm (3.8266 0.0006 inch)Bore in head for valve seat inserts ... 97.000 0.025 mm (3.8189 0.0010 inch) (14) Angle of face of valve seat inserts Inlet ... 20.75 0.15 degreesExhaust ... 30.75 0.15 degreesFull face contact is required between both the valve and the insert for the full 360 degrees. The minimum width of the seat is the following dimension. ... 3.0 mm (0.12 inch) (15) Maximum recess from the closed valve face to the surface of the cylinder head ... 2.0 mm (0.08 inch)Maximum projection of the closed valve above the surface of the cylinder head ... 0.50 mm (0.020 inch) (16) Outside diameter of the head of the inlet valve ... 90.00 0.20 mm (3.543 0.008 inch)Outside diameter of head of the exhaust valve ... 90.00 0.20 mm (3.543 0.008 inch) (17) The minimum valve lip thickness that can be used again is the following dimension. ... 5.40 mm (0.213 inch)