0383713 JOHNSON GEARCASE EXTENSION ASSEMBLY 5" EXTENSION KIT

Start By:a. remove exhaust manifoldb. remove air inlet manifoldc. remove fuel injection linesd. remove fuel injection nozzles 1. Drain the coolant from the cooling system into a suitable container for storage or disposal.2. Remove clamp (1) from water sleeves (2) in each cylinder head assembly. Push the water sleeves into the timing gear cover with Tool (A) and a screwdriver.3. Remove bolt (3) from the bracket on the dipstick tube. 4. Remove bolts (4) and stud (5) from the heads.
Make sure the fuel injection nozzles are removed before the cylinder head assemblies are removed. The fuel injection nozzles go through the cylinder head assemblies and the nozzle tips can be broken off if the nozzles are not removed from the heads.
5. Install Tooling (B), and fasten a suitable lifting device. Remove bolts (7), cylinder head assembly (6) and the gasket. The weight of the cylinder head assembly is 54 kg (120 lb).Install Cylinder Head Assemblies
Check the cylinder head and block for top deck flatness. The flatness of the cylinder head and block should be within 0.15 mm (.006 in) total, and a maximum of 0.08 mm (.003 in)for any 152.4 mm (6.00 in)span.1. Clean the contact surfaces of the cylinder head assembly and cylinder block. Make sure the surfaces are clean and dry. Install a new cylinder head gasket (2). Clean the bore in the cylinder head assembly for the water sleeves. Put oil on the seals on the water sleeves.2. Install Tooling (A) in the cylinder head assembly. Fasten a suitable lifting device, and put cylinder head assembly (1) in position on the cylinder block.
Bolt head identification.
The higher cylinder head bolt torque may be used on earlier engines ONLY if the bolts are replaced with the later higher strength bolts (seven dash marks on the bolt head). If the earlier bolts are tightened to the later torque specification, they may yield (stretch) and lose their clamping force.
3. Put 6V-4876 Molykote Lubricanton the bolt threads, and install the bolts that hold the cylinder head assembly in place. Tighten the bolts in the cylinder head assembly according to the following procedure: 4. Install water sleeve (3) into the cylinder head assembly with Tool (B) and a screwdriver.5. Install bolt (4) which holds the dipstick tube to the cylinder head assembly. 6. Install clamp (5) on the water sleeves.7. Fill the cooling system with coolant to the correct level. See the Operation & Maintenance Manual. For more detailed information regarding the cylinder head assemblies, see the topic "Cylinder Head" in the Specifications Manual.End By:a. install fuel injection nozzlesb. install fuel injection linesc. install air inlet manifoldd. install exhaust manifoldDisassemble Cylinder Head Assemblies
Start By:a. remove cylinder head assemblies 1. Fasten a suitable lifting device, and put the cylinder head assembly in position on Tool (A). Use adapter plates (1) from Tooling (A) to hold the head in place. 2. Put the valve springs under compression with Tool (C).3. Remove the locks from the valves.4. Remove Tool (C), the retainer, spring, washer and valve from the cylinder head. Put identification marks on the valve as to its location in the cylinder head. 5. Check the valve spring force with Tool (B). For the correct spring force, see the topic "Valves" in the Specifications Manual.6. Do Steps 2 through 5 for the remainder of the valves. 7. Remove the valve seat inserts with tooling (D). The valve guides are part of the cylinder head. Measure the bore in each valve guide 19.0 mm (.75 in) from the outside edge on both ends of each valve guide. The bore must be 9.512 0.013 mm (.3745 .0005 in). The maximum permissible bore is 9.550 mm (.3760 in). Valve guides worn more than the maximum specification can be made to the original size by knurling.Assemble Cylinder Head Assemblies
1. Clean and remove burrs and all foreign material from the valve seat bores.
Do not make the diameter of the extractor [part of Tooling (A)] in valve seat insert larger when the insert is installed in the cylinder head.
2. Lower the temperature of the valve seat inserts, and install them with Tooling (A).3. Grind the valve inserts according to the dimensions given in the Specifications Manual. 4. Put clean engine oil on the valve stem. Install the valve, washer (3), springs (2) and retainer (1) in the cylinder head. 5. Put the valve springs under compression with Tool (C).6. Install the locks on the valve stem with Tool (B).
Make sure locks (4) are in their correct position on the valve. The locks can be thrown from the valve when Tool (C) is released if the locks are not in their correct position on the valve.
7. Remove Tool (C), and hit the valve with a rubber hammer to be sure the locks are in their correct position.8. Do Steps 4 through 7 for the remainder of the valves. For more detailed information regarding the cylinder head assemblies, see the topic "Cylinder Head" in the Specifications Manual.End By:a. install cylinder head assemblies