0386162 JOHNSON HEAD,Crankcase

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1U-9352 Engine Stand 1
8T-2826 Head Adapter 1
B - Fabricated Plate (1) 1
- Fabricated Plate (2) 1
8T-2679 Valve Guide Rod 1
1D-4720 Nut 2
C 8T-2660 Valve Spring Compressor 1
515–1161 Valve Spring Compressor Tool (3) -
8F-6350 Bolt 1
5B-2638 Bolt 1
4B-5271 Washer 1
F 8T-2676 Valve Guide Driver 1
J 4C-8540 Dowel Driver 1
K 4C-8769 Valve Seat Driver 1
L 8T-2674 Valve Seat Driver 1
M FT-1741 Vacuum Tester 1
N 4C-9500 Quick Cure Primer -
P 4C-9507 Retaining Compound -
Q 8T-2998 Lubricant -
(1) Fabricate the plate from 6.4 mm (0.25 inch) flat stock. The outside dimensions of the plate are 32 mm (1.25 inch) by 133 mm (5.25 inch). Drill a 16.5 mm (0.65 inch) hole in the center.
(2) Fabricate the plate from 6.4 mm (0.25 inch) flat stock. The outside diameter is 203 mm (8 inch). Drill a 16.5 mm (0.65 inch) hole in the center.
(3) This tool is an alternative Valve Spring Compressor Tool.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Install the cylinder head on Tooling (A). The weight of the cylinder head is approximately 205 kg (450 lb).
If the O-ring seals were removed from the valve guides, install new O-ring seals in the valve guides.
Illustration 1 g01213114
Lower the temperature of bridge dowels (11) to −70 °C (−94 °F). Use Tooling (J) to install the bridge dowels to a height of Dimension (Y) above the cylinder head. Dimension (Y) is 105 2.0 mm (4.1 0.08 inch).
Illustration 2 g01213116
Lower the temperature of valve guides (9) to −70 °C (−94 °F). Use Tooling (F) to install the valve guides to a height of Dimension (W) above the cylinder head. Dimension (W) is 20 2.0 mm (0.8 0.08 inch).The correct inside diameter of the valve guide after installation is 16.031 0.028 mm (0.6311 0.0011 inch).
Do not use a hammer to install the valve seats. The use of a hammer will damage the valve seats and the cylinder head. Only use a suitable press for installation of the valve seats.
Illustration 3 g01213121Note: Do not lower the temperature of valve seats (8). Make sure that the valve seats are at room temperature before installation.
Apply Tooling (N) to the outside of the valve seats. Then apply Tooling (P) over Tooling (N).
Use Tooling (K) and a suitable press to install the valve seats for the inlet valves. Press the valve seats into the bottom of the counterbore in the cylinder head.
Use Tooling (L) and a suitable press to install the valve seats for the exhaust valves. Press the valve seats into the bottom of the counterbore in the cylinder head.
Inspect valves (7). If necessary, use a fine stone that is properly dressed for grinding the faces of valves (7). Grind the valves only enough to restore the faces.
Lubricate valves (7) with Tooling (Q). Install valves (7) into the original positions in the cylinder head.