0382291 JOHNSON HEAD AND BEARING

Manual Barring Device or Air Wrench Drive Barring Device (If Equipped)
Lubricate Manual Device (1:1 Ratio)
Lubricate the pinion gear with grease (MPGM). Use a hand operated grease gun and apply one pump of grease to the grease fitting.Lubricate Air Wrench Device (50:1 Ratio)
Lubricate the grease fitting with grease (MPGM) until grease is visible around the shaft.Valve Lash, Valve Bridge, Injector Timing & Synchronization
Check/Adjust
Initial valve lash adjustment for new or rebuilt engines only, is recommended at the initial 3 Month maintenance interval. This is due to the initial wear and seating of valve train components.The next adjustment should be made at the Every 6 Month maintenance interval. If unchanged at the first 6 Month interval, make future adjustments at Every One Year interval thereafter.If an adjustment was performed at the first 6 Month interval, make future adjustments at Every 6 Month inspection interval until unchanged, then make future adjustments at Every One Year interval thereafter.Thoroughly clean the area around the valve mechanism covers to prevent the entry of foreign matter into the top of the cylinder head and valve mechanism.
DO NOT use the air or electric starters to rotate the engine. If the engine is rotated too fast, oil cannot flow through the openings in the cylinder head fast enough to prevent damage to the combustion seal.
Be sure the starting motors are disabled and engine cannot be started while this maintenance is being performed. This is very important when the engine is equipped with an automatic start-stop system.
Before operating barring device or turning the crankshaft, operate the prelube pump to ensure correct prelube procedure. DO NOT crank the engine before prelube, especially after this maintenance procedure, to prevent damage to the crankshaft bearings.
Prelubing the engine is required when the crankshaft is rotated during normal maintenance operations; this includes adjusting valves. Use the air or manual barring group (if equipped) to turn the crankshaft to the TC position.The manual barring device provides the ability to turn the flywheel and crankshaft. When the barring group gear shaft is engaged, the starting system is disabled.The engine should be prelubed prior to rotating the engine crankshaft with the barring group. The prelube pump should also be left ON during the time the engine crankshaft is rotated.
The lube oil can drain out from between the crankshaft and engine bearings if the engine has not been run for a period of time. Damage can result if the crankshaft is rotated on dry bearing surfaces.
The intermittent prelube pump should not be operated continuously for extended periods of time. If, during repairs, the intermittent prelube pump has run continuously for a period of three hours or more, it will be necessary to remove any oil that may have collected in the cylinders and/or above the valves.The gear shaft is spring loaded and must be pushed toward the flywheel to engage the pinion with the flywheel ring gear. The barring group handle is used to secure the gear shaft in the engaged or disengaged positions.Rotate the adapter to turn the crankshaft and the crankshaft and flywheel will be locked into the engaged position. To lock the flywheel and crankshaft from turning, tighten guide to a torque of 270 25 N m (200 18 lb ft).
3606 Engine
3608 Engine Adjust the valve bridges first. See valve bridge adjustment in the Service Manual for the procedure. 1Valve lash is measured between the rocker arm and the bridge for the valves. Adjust the clearance to the value specified in the chart. Be sure to adjust the valve bridges before adjusting the valves.When the valve lash (clearance) is checked, an adjustment is NOT necessary if the measurement is within 0.08 mm ( 0.003 in.) of the value given in the chart.Valve Bridge
Before adjusting valve lash, a bridge adjustment must be made. Refer to the topic Valve Lash, Valve Bridge and Injector Timing & Synchronization in the Service Manual for the procedure.Injector Timing
Refer to the topic Valve Lash, Valve Bridge and Injector Timing & Synchronization in the Service Manual for the procedure.Injector Synchronization
Refer to the Service Manual for the correct procedure on Injector Synchronization.Engine Oil Filters
Refer to the Safety section and Lubricant Specifications topic of this manual for the recommended oil to use for this engine.
This maintenance is required at Every 6 Weeks if the engine is operating on heavy fuel or Every 3 Months if operating on distillate fuel. Refer to the maintenance schedule for the proper interval for your engine. Change the oil filters any time the oil pressure differential reading approaches 100 kPa (15 psi), S O S Analysis determines condemning limits or Every 3 Month inspection or 72 500 km (45,000 miles), whichever occurs first.Replace
Additional service tools are available for servicing the oil filters. The 8T2850 Tool Group includes the 1U9824 Tool Group for the oil filter.
Use caution when draining oil or changing filter elements. Filter contains hot pressurized fluid when engine is running. Follow the instructions on the control valve to avoid personal injury.If rapid air movement exists that could blow hot oil, STOP the engine to avoid fire.Hot oil and components can cause personal injury. DO NOT allow hot oil or components to contact skin.
The 8T2850 Tool Group service tool should be installed for filter servicing and removed afterwards. Some owners of earlier 8T2850 Tool Groups will need to order the 1U9824 Tool Group to aid with the engine oil filter servicing.The 1U9824 Tool Group consists of the following components.* 1U9823 Filter Scoop Assembly - used to remove the dirty oil filters.* 1U9821 Lower Tray Assembly - used to drain the lower oil filter housing and collect the oil from the upper oil filter housing. The tray includes a tube connection for a customer-supplied 25.4 mm (1.00 in) inside diameter drain hose.* 1U9822 Upper Tray Assembly - used to drain the upper oil filter housing into the 1U9821 Lower Tray Assembly.