0435157 JOHNSON ENGINE COVER ASSY.

At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water or steam. Any contact can cause severe burns. Look at the sight gauge to check the coolant level. The coolant level should be in the green range. If necessary, remove the fill cap only after the engine has been stopped and the cap is cool enough to remove with your bare hand. Remove the cooling system fill cap slowly to relieve pressure. Cooling system condition contains alkali that can cause personal injury. Avoid contact with the skin and eyes and do not drink. Allow cooling system components to cool before draining.
1. Drain the coolant from the cooling system to a level below the engine oil cooler. 2. Disconnect and plug two hoses (1) from the oil cooler bypass body.3. Disconnect and plug hose (2) from the oil cooler bypass body. 4. Remove four bolts (3) that secure the oil cooler bypass body to the side of the engine. 5. Remove two bolts (5) that secure the oil cooler bypass body bracket to the side of the engine.6. Remove O-ring seal (4) from the adapter on the oil cooler bypass body. 7. Remove bolt (6) and the washers and nut that secure tube (7) to the bracket.8. Place tube (7) away from the engine oil cooler. 9. Remove two bolts (9) and the washers that secure bonnet (10) to bracket (8). 10. Remove six bolts (11) that secure bonnet (10) to the brake oil cooler. 11. Remove one bolt (12), the washer, and bracket and spacer from bonnet (10).12. Remove the remaining five bolts (13) that secure bonnet (10) to the side of the engine.13. Remove bonnet (10) from the engine oil cooler and the transmission oil cooler.14. Remove the gasket from the side of the engine. Remove two O-rings from bonnet (10) at the location where engine oil cooler (14) connects.15. Remove two O-ring seals from the transmission oil cooler at the location where bonnet (10) connects.16. Remove engine oil cooler (14) from the engine. The weight of engine oil cooler (14) is approximately 20 kg (44 lb).17. Remove the two O-ring seals from the cooler inlet bonnet.18. Remove the four O-ring seals on the oil cooler bypass body. The following steps are for the installation of the engine oil cooler.
Prior to installation, check all parts of the engine oil cooler for damage or wear. Replace a damaged or worn part with a new part, if necessary.
19. Lubricate two O-ring seals with clean engine oil. Install the two O-ring seals on the cooler inlet bonnet end.20. Lubricate four O-ring seals with clean engine oil. Install the four O-ring seals in the oil cooler bypass body that seal the oil cooler bypass body and the engine.21. Place engine oil cooler (14) in position in the cooler inlet bonnet.22. Install the two O-ring seals in bonnet (10) that seals bonnet (10) and the transmission oil cooler.23. Place the gasket in position between bonnet (10) and the engine.24. Install bonnet (10) on the oil coolers.25. Install five bolts (13). Install one bolt (12), the spacer, washer and bracket in bonnet (10). 26. Install six bolts (11) that secure bonnet (10) to the brake oil cooler. 27. Install two bolts (9) and the washers that secure bonnet (10) to bracket (8). 28. Install bolt (6), the washers and nut that secure tube (7) to the bracket. 29. Install two bolts (5) that secure the oil cooler bypass body to the engine.30. Install O-ring seal (4) in the adapter. 31. Install four bolts (3) that secures the oil cooler bypass body to the engine. 32. Install two hoses (1) on the oil cooler bypass body.33. Install one hose (2) on the adapter on the side of the oil cooler bypass body.34. Refill the coolant system with the proper coolant. Refer to the Operation & Maintenance Manual SEBU6968 for the correct capacity and fluid.End By:a. install crankcase guards