0436769 JOHNSON GEARCASE ASSY., Complete

Start By:a. remove exhaust manifoldb. remove the valve cover The exhaust manifolds do not have to be removed unless all the cylinder head assemblies are to be removed.1. Drain the coolant from the cooling system.2. Shut off the fuel supply at the fuel tank. 3. Remove fuel lines (1) from the each cylinder head assembly and fuel manifold (2).4. Remove the support clips and fuel manifold (2) from manifold (3)
Typical Example5. Remove water manifold (3). Air inlet elbow (4) does not have to be removed from the cylinder head assembly, only the bolts that hold the elbow to the cylinder head assembly.6. Remove the bolts from air inlet manifold (4). 7. Remove rocker shaft assembly (6) and push rods (8).8. Disconnect wire (7). 9. Remove the nuts and the wire harness from unit injector (9). Remove the clamp holding injector (9).10. Remove electronic unit injector (9). See the topic "Remove & Install Electronic Unit Injector" in this module.11. Remove the bolts and valve cover base (10). Remove the gasket and O-ring seals from beneath valve cover base (10). 12. Remove bridge assemblies (11).13. Fasten tooling (B) to the cylinder head using the threaded holes for the valve cover base. Support the cylinder head with a hoist.14. Remove eight bolts (12) and two bolts (13) to remove the cylinder head from the engine block. The weight of the cylinder head assembly is 47 kg (105 lb.).15. Repeat Step 6 through Step 14 to remove the remaining cylinder head assemblies. 16. Remove head gasket (14), the seals, the spacer plate and spacer plate gasket from the engine. The following steps are for installing the cylinder heads. Thoroughly clean the spacer plate and bottom surface of the cylinder head assembly. A new spacer plate gasket must be installed when the cylinder head assembly is removed.17. Install head gasket (14), the spacer plate and spacer plate gasket. Refer to the topic "Install Spacer Plate" in this module for further information.
The plug at location (A) MUST be installed in the cylinder head for this engine.
18. Fasten a hoist to the cylinder head assembly. Position the cylinder head assembly onto the spacer plate. 19. Put 5P3931 Anti-Seize Compound on the threads of cylinder head bolts (12) and (13). Install the cylinder head bolts and washers. Tighten the bolts in the following sequence:a. Tighten bolts (12) in the numbered sequence to a torque of 30 5 N m (22 4 lb. ft.).b. Tighten bolts (12) in the numbered sequence to a torque of 200 15 N m (148 11 lb. ft.).c. Tighten bolts (12) in the numbered sequence to a torque of 200 15 N m (148 11 lb. ft.).d. Turn bolts (12) again by an additional 180 degrees.e. Tighten bolts (13) to a torque of 55 10 N m (40 7 lb ft).20. Remove tooling (B).21. Make sure the O-ring seals are installed around the two dowels in the bottom of valve cover base (3). Put the gasket and base (3) in position. Install valve cover base (3) to the cylinder head.22. Reverse the procedures and steps 1 through 12. Make sure all surfaces are clean. Replace all gaskets. Lubricate the O-ring seals with clean engine oil when assembling. See the topic "Cylinder Heads" in the Specifications and the Systems Operation/Testing & Adjusting modules for further information.End By:a. install the exhaust manifoldb. install the valve cover