0433564 JOHNSON MANIFOLD AY

Table 1
Required Tools
Tool Part Number Part Description Qty
A 439-3938 Link Bracket 2
B - Loctite C5A Copper Anti-Seize -
C -- Loctite 517 Thread Sealant -
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01121095Note: Thoroughly clean the spacer plate and the bottom surface of the cylinder head and the top of the cylinder block. A new spacer plate gasket and a cylinder head gasket must be installed when the cylinder head is removed.
Install O-ring seal (15) on the dowel. Install gasket (14).
Install spacer plate (12). Install seals (10) and seals (11). Install O-ring seal (13).
Check the cylinder liner projection. Refer to Testing and Adjusting, "Cylinder Liner Projection".
Illustration 2 g01120717
Apply Tooling (C) to pipe plug (8). Pipe plug (16) MUST be installed in cylinder head (8).
Apply Tooling (B) to the threads of pipe plug (17).
Install cylinder head gasket (9) on the spacer plate.
Install Tooling (A) and a suitable lifting device on cylinder head (8). The weight of cylinder head (8) is approximately 47 kg (104 lb).
Illustration 3 g01121159
Carefully install cylinder head (8) on the dowel pins on the cylinder block.
Apply Tooling (B) to the threads of bolts (3). Position gasket (2) and install bolts (3). Tighten the bolts to a torque of 50 5 N m (37 4 lb ft).
Coat the threads of bolts (6) and (7) with clean engine oil. Install bolts (6) and (7) according to the instructions in Step 11 and Step 12.Note: Only 254 mm (10 inch) bolts (6) can be used for the following torque procedures.
Illustration 4 g06338934
Tightening sequence with 362-8264 Cylinder Head Gasket (MLS) and 110-6994 Spacer Plate (Aluminum) or 362-9677 Spacer Plate (Aluminum).Note: Refer to Illustration 4 for the correct tightening sequence.
Tighten bolt (1) through bolt (8) to a torque of 30 5 N m (22 4 lb ft).
Tighten bolt (1) through bolt (8) to a torque of 100 15 N m (75 11 lb ft).
Tighten bolt (1) through bolt (8) to a torque of 450 15 N m (332 11 lb ft).
Loosen bolt (1) through bolt (8) an angle of 90 degrees.
Tighten bolt (1) through bolt (8) to a torque of 490 15 N m (361 11 lb ft).
Tighten bolt (9) and bolt (10) to a torque of 55 10 N m (40 7 lb ft).
Illustration 5 g06338934
Tightening sequence with 362-8264 Cylinder Head Gasket (MLS) and 519-7297 Spacer Plate (Iron).Note: Refer to Illustration 5 for the correct tightening sequence.
Tighten bolt (1) through bolt (8) to a torque of 30 5 N m (22 4 lb ft).
Tighten bolt (1) through bolt (8) to a torque of 145 15 N m (107 11 lb ft).
Tighten bolt (1) through bolt (8) to a torque of 145 15 N m (107 11 lb ft).
Turn bolt (1) through bolt (8) an angle of 180 5 degrees.
Tighten bolts (9) and (10) to a torque of 55 10 N m (40 7 lb ft).
Illustration 6 g01121204
Position gasket (5) and install bolts (4).
Install the O-ring seal and the integral seal on tube (1). Install tube (1).
Fill the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".End By:
Install the valve mechanism cover base.