5005010 JOHNSON ENGINE COVER Assy

Table 1
Required Tools
Tool Part Number Part Description Qty
B - Guide Studs
M16 by 115mm 2
C 8T-3052 Degree Wheel 1
D 1U-6396 O-Ring Assembly Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Thoroughly clean the gasket surfaces of the cylinder head and the cylinder block. Do not damage the gasket surfaces of the cylinder head or the cylinder block. Ensure that no debris enters the cylinder bores, the coolant passages, or the lubricant passages.
Inspect the gasket surface of the cylinder head for distortion. Refer to Specifications, "Cylinder Head" for more information. If the gasket surface of the cylinder head is distorted beyond maximum permitted limits, replace the cylinder head.
Illustration 1 g02717296
Inspect dowels (20) for damage. If necessary, replace the dowels in the cylinder block.
Install Tooling (B) to the cylinder block.
Align a new cylinder head gasket (21) with dowels (19). Install the new cylinder head gasket (20) onto the cylinder block.
Use a suitable lifting device to lift cylinder head. The weight of the cylinder head is approximately 96 kg (212 lb). Note: A spreader bar must be used in order to distribute the weight of the cylinder head during the lifting operation.
Use Tooling (B) to align the cylinder head with the cylinder block. Install the cylinder head to the cylinder block. Note: Ensure that the cylinder head is correctly positioned on dowels (20).
Remove Tooling (B).
Illustration 2 g02717298
Clean bolts (18). Follow Step 9.a for the procedure to inspect the bolts.
Use a straight edge to check the threads of the bolts. Refer to Illustration 2. Replace any bolts that show visual reduction in the diameter of the thread over Length (Y).
Lubricate the threads and the shoulder of bolts (18) with clean engine oil.
Illustration 3 g02717339
Illustration 4 g02717340
Install bolts (18) to cylinder head (19).
Tighten the bolts to a torque of 50 N m (37 lb ft) in the numerical sequence that is shown in Illustration 4.
Tighten the bolts to a torque of 160 N m (118 lb ft) in the numerical sequence that is shown in Illustration 4.
Use Tooling (C) in order to turn the bolts through an additional 130 degrees in the numerical sequence that is shown in Illustration 4.
Illustration 5 g02717238
Use Tooling (D) in order to lubricate new O-ring seal (16) and O-ring seal (17). Install O-ring seal (16) and O-ring seal (17) to bypass tube (15).
Install the bypass tube in the cylinder head. Install bolts (14). Tighten the bolts to a torque of 22 N m (195 lb in).
Illustration 6 g02717217
Illustration 7 g02717219
Install bolts (12) to the clips for tube assembly (13). Tighten the bolts to a torque of 44 N m (32 lb ft).
Remove plugs from plastic tube assembly (6) and plastic tube assembly (8).
Remove caps from connections on fuel injection pump (7)
Connect plastic tube assembly (6) and plastic tube assembly (8) to fuel injection pump (7).
Position bracket (5) and bracket (10) onto cylinder head.
Install bolts (4) and bolts (9) to bracket (5) and bracket (10). Tighten the bolts to a torque of 22 N m (195 lb in).
Position bracket (2) onto the cylinder head. Install bolt (3) to the bracket. Tighten the bolt to a torque of 22 N m (195 lb in).
Connect the tube assembly and hose assembly from connection (11). Tighten hose the clamp securely.
If necessary, install the tube assembly from the cylinder head and the boost control on the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump- Install (With Boost Control)" for the correct procedure.
Illustration 8 g02717216
If necessary, install water temperature regulator housing (1) to the cylinder head. Refer to Disassembly and Assembly, "Water Temperature Regulator Housing - Remove and Install" for the correct procedure.
Connect the upper radiator hose to water temperature regulator housing (1) on the cylinder head. Tighten hose clamp securely. End By:
Install the rocker shaft and pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrods - Install" for the correct procedure.
Install the fuel injectors. Refer to Disassembly and Assembly, "Fuel Injector - Insta