0435237 JOHNSON ENGINE COVER ASSY.

1. Remove the muffler. Remove the hood. The weight is 55 Kg (120 lb.). Remove the air cleaner housing. 2. Disconnect two hose clamps (1), and remove hose. Remove nuts (2), and remove dust ejector tube (3).3. Remove bolts (4), and remove elbow (5). Disconnect two electrical wires (6). 4. Remove bolt (7), and remove pipe (8) from the turbocharger. Remove four bolts (9), and remove pipe assembly (10). 5. Remove bolts (11) that hold the valve covers to the valve cover bases. Remove valve covers (12) and (13). 6. Remove bolts (14) that hold the valve cover bases to the cylinder head assembly. Remove valve cover bases (15).
To prevent damage to the fuel injection nozzle, hold adapter assembly (16) in position at the top of injection nozzle (17) when fuel line nut (18) is loosened or tightened.
7. Use tool (A) and a 5P328 Crowfoot Wrench (7/8") to loosen the fuel injection line nut at the nozzle end. 8. Use tool (B) to loosen the nut at the fuel injection line adapter end. Remove inner fuel injection lines (19). Install caps and plugs on all fuel injection line openings to keep dirt out of the fuel system. 9. Remove bolts (20) that hold the rocker shaft assemblies to the cylinder head assembly.10. Remove rocker shaft assemblies (21). 11. Put identification marks on the push rods as to their location in the engine. Remove push rods (22). 12. Put identification marks on the bridges as to their location in the engine. Remove bridges (23) from the dowels on the cylinder head assembly.Install Rocker Shaft Assemblies And Push Rods
1. Put clean engine oil on the bridges and dowels. Install the original briges in their respective locations. New bridges can be mixed.2. Install bridges (23) on the bridge dowels. While firmly pressing 0.5 to 4.5 Kg (1 to 10 lb.) straight down on the top contact surface of the bridge, turn the adjusting screw clockwise until contact is made with the valve stem. Turn the screw an additional 20° to 30° (1/3 to 1/2 of 1 hex on nut). This will straighten the dowel in the guide and compensate for the slack in the threads. Hold the adjusting screw in this position, and tighten the locknut to a torque of 30 4 N m (22 3 lb.ft.). Install original push rods in their respective locations in the engine. New push rods can be mixed.3. Install push rods (22). 4. Put rocker shaft assemblies (21) in position on the cylinder head assembly.5. Put clean engine oil on the threads of the bolts that hold the rocker shaft assemblies in place. Tighten the bolts first to a torque of 270 25 N m (200 18 lb.ft.). Start with the bolt in the center of the rocker shaft assembly. Tighten the bolts again to a torque of 450 20 N m (330 15 lb.ft.). Tighten the bolts again by hand to a torque of 450 20 N m (330 15 lb.ft.).
Do not cause damage to the O-ring seals on the inner fuel lines.
6. Install inner fuel injection lines (19). Tighten the fuel injection line adapter nuts (24) to a torque of 40 7 N m (30 5 lb.ft.) with tool (A).
Do not let the tops of the fuel nozzles turn when the fuel lines are tightened. The nozzles will be damaged if the top of the nozzles turns in the body.
7. Tighten fuel injection line nut (25) to a torque of 40 7 N m (30 5 lb.ft.) with tool (B) and a 5P328 Crowfoot Wrench (7/8").8. Make adjustments to the valves until the intake valve clearance is 0.38 mm (.015 in.) and the exhaust valve clearance is 0.76 mm (.030 in.). See the topic, Valve Clearance Setting in Testing And Adjusting. Tighten the locknut to a torque of 30 4 N m (22 3 lb.ft.) and check the adjustments. 9. Install valve cover bases (15) on the cylinder head assembly. Install bolts (14) that hold the valve cover bases in place. Tighten the bolts to a torque of 14 3 N m (10 2 lb.ft.). 10. Put valve covers (12) and (13) in position on the valve cover bases. Install bolts (11), and tighten the bolts to a torque of 14 3 N m (10 2 lb.ft.). 11. Put pipe assembly (10) in position, and install it with bolts (9). Install pipe (8), and secure it in position with bolt and washer (7). 12. Connect electrical wires (6). Install elbow (5) with bolts (4).13. Put dust ejector tube (3) in position, and install it with nuts (2). Install hose with two hose clamps (1).14. Install the hood and the muffler. Install the air cleaner housing.Disassemble And Assemble Rocker Shaft Assemblies
Start By:a. remove rocker shaft assemblies and push rods 1. Remove retainer (2) from the end of the shafts.2. Remove the washers and rocker arms (1). 3. Remove pins (6) that hold the brackets to each end of the shaft. The center bracket does not have a pin.4. Remove bracket (3), rocker arm (4) and spring (5).5. To inltall, put clean engine oil on the shaft.6. Install the bracket and rocker arms for the center bracket.7. Install spring (5), rocker arm (4) and bracket (3). Install the pin that holds the brackets on each end of the rocker shaft. Install the pin until it extends 12.7 1.0 mm (.50 .04 in.) from the surface of the bracket. 8. Install rocker arm (4) on each end of the shaft. Install washers (6) as needed to get an assembled clearance of .030 to 1.40 mm (.0012 to .055 in.) at each end of the shaft. Install the retainer on each end of the shaft.End By:a. install rocker shaft assemblies and push rods