5034306 JOHNSON **KEY (933)

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     138-7575     Link Bracket     2    
B     6V-4876     Lubricant     -    
C     8T-3096     Hand Tap     1    
D     6V-6640     Sealant     -    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Thoroughly clean the mating surfaces of the cylinder head and the cylinder block.
Clean all 26 head bolt holes on the cylinder block with Tooling (C) .
After cleaning the threads, remove any debris from the head bolt holes on the cylinder block with a vacuum hose.
Visually inspect the head bolt holes on the cylinder block for thread damage.
If a damaged head bolt thread is observed, repair the damaged head bolt thread with a Heli-Coil thread repair kit.
Inspect the cylinder head and the cylinder block for flatness. Refer to Guideline for Reusable Parts and Salvage Operations, SEBF8162, "Procedure to Measure and Salvage Cylinder Head Assemblies and Related Components".
Install the correct cylinder head gasket on the cylinder block.Note: To avoid damage to the cylinder head gasket, use guide bolts of an appropriate size to install the cylinder head.
Attach Tooling (A) and a suitable lifting device to the cylinder head. The weight of the cylinder head is approximately 184 kg (405 lb).
Illustration 1 g01801014
Install cylinder head (22) .
Install new cylinder head bolts (20) . If the engine is equipped with a compression brake, then also install new head bolt studs.
Lubricate the bolt threads, the underside of the bolt heads, and the washers with Tooling (B) prior to assembly. Follow Step 12 for the correct tightening procedure.
Illustration 2 g00950659
Tighten the cylinder head bolts according to the following procedure:
Tighten bolt (1) through bolt (26) in a numerical sequence to a torque of 170 10 N m (125 7 lb ft).
Tighten bolt (1) through bolt (26) again in a numerical sequence to a torque of 170 10 N m (125 7 lb ft).
Place a mark on bolt (1) through bolt (26) . Rotate bolt (1) through bolt (26) in a numerical sequence for an additional 120 5 degrees (1/3 turn).
Loosen bolt (1) through bolt (26) until the washers are loose under the bolt heads.
Tighten bolt (1) through bolt (26) in a numerical sequence to a torque of 170 10 N m (125 7 lb ft).
Tighten bolt (1) through bolt (26) again in a numerical sequence to a torque of 170 10 N m (125 7 lb ft).
Place a mark on bolt (1) through bolt (26) . Rotate bolt (1) through bolt (26) in a numerical sequence for an additional 120 5 degrees (1/3 turn).
Tighten bolt (27) through bolt (34) in a numerical sequence to a torque of 55 10 N m (41 7 lb ft).
Illustration 3 g01018718
View A-ANote: Lubricate the bores for the cup plugs with Tooling (D) prior to installing the cup plugs. The cup plugs are measured from the head face to the top edge of the plug.
Install the cup plugs to a depth (23) of 1.25 0.25 mm (0.049 0.010 inch).Note: The minimum permissible thickness of cylinder head should be the following value 104.35 mm (4.108 inch). The flatness of the cylinder head should be within 0.15 mm (0.006 inch). The flatness should also be a maximum of 0.05 mm (0.002 inch) for any 150.00 mm (5.906 inch) span.
Illustration 4 g01018271
Connect harness assembly (14) .
Illustration 5 g01018269
Connect the following items: clip (8) , wire assembly (10) and harness assembly to sensor (12) . Connect hose assembly (9) to the cylinder head. Install bolt (11) .
Illustration 6 g01018267
Connect hose assemblies (5) and (6) . Connect clamp (4) to the cylinder head. Install bolts (7) .
Illustration 7 g01018266
Install air tube assembly (1) . Connect hose assembly (2) . Move harness assembly (3) in place. Install all cable straps that connect harness assembly (3) to the cylinder head.End By:
Install the precooler. Refer to Disassembly and Assembly, "Precooler - Install".
Install the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Install".
Install the turbochargers. Refer to Disassembly and Assemb