0435235 JOHNSON ENGINE COVER ASSY.

Bracket (2) is on earlier machines only.1. Remove the bolts and bracket (2) from the plate.2. Remove gauge line (1) from the cylinder head. Disconnect line (4) from the tee if equipped. Disconnect glow plug wire (7) from each end of the cylinder head. Disconnect water line (5) from the air compressor.3. Remove bolts (3) and (6) that hold the cylinder head to the cylinder block. 4. Fasten a hoist and a spreader bar to the cylinder head as shown. Remove cylinder head (8). Weight is 204 Kg (450 lb.). Remove exhaust manifold (9) from the cylinder head.
Do not put the cylinder head down on a flat surface. This can cause damage to the fuel injection valves.
Install Cylinder Head Assembly
Be sure a new gasket has been installed between the spacer plate and the cylinder block. See the topic, Remove and Install Spacer Plate.1. Thoroughly clean the spacer plate and the bottom surface of the cylinder head. Install a new head gasket and new seals.2. Install the exhaust manifold on the cylinder head. Install the nuts that hold it.3. Fasten a hoist and a spreader bar to the cylinder head. Put cylinder head (8) in position on the cylinder block. 4. Put clean engine oil on the threads of the cylinder head bolts. Install the cylinder head bolts and washers. Tighten the bolts in following sequence:a. Tighten bolts 1 through 20 in number sequence to 270 25 N m (200 18 lb.ft.).b. Tighten bolts 1 through 20 in number sequence to 450 20 N m (330 15 lb.ft.).c. Tighten bolts 1 through 20 in number sequence to 450 20 N m (330 15 lb.ft.) by hand.d. Install rocker shafts (4) and push rods.e. Tighten bolts 21 through 26 in number sequence to 450 20 N m (330 15 lb.ft.).g. Tighten bolts 21 through 26 in number sequence to 450 20 N m (330 15 lb.ft.).f. Tighten bolts 21 through 26 in number sequence to 450 20 N m (330 15 lb.ft.).g. Tighten bolts 21 through 26 in number sequence to 450 20 N m (330 15 lb.ft.) by hand.h. Tighten the 3/8" bolts (5) to 43 7 N m (32 5 lb.ft.). If studs (6) were removed, inltall new studs and tighten to 25 4 N m (18 3 lb.ft.).5. Make an adjustment to the valves to have a clearance of 0.38 0.07 mm (.015 .003 in.) for intake, and 0.76 0.07 mm (.030 .003 in.) for exhaust. Install valve cover bases and the inner fuel lines. See the topic, Install Rocker Shaft Assemblies And Push Rods. Bracket (2) is on earlier machines only.6. Install the muffler support bracket (2). Install gauge line (3) in the cylinder head. Connect the line to tee (2). If equipped, connect the two glow plug wires. Connect the water line to the air compressor.End By:a. install inlet manifoldb. install fuel injection linesc. install water temperature regulatord. install rocker shafts and push rodse. install hood and muffler