0209792 JOHNSON OWNER'S MANUAL

Table 1
Required Tools
Tool Part Number Part Description Qty
A - E14 Torx 1/2 Inch Drive Socket 1
B 227-4393 E18 Torx 1/2 Inch Drive Socket 1
C 8T-3052 Degree Wheel 1
D - Guide Bolt
(M12 by 115mm) 1
E - Straight Edge 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Thoroughly clean the gasket surfaces of the cylinder head and the cylinder block. Do not damage the gasket surfaces of the cylinder head or the cylinder block. Ensure that no debris enters the cylinder bores, the coolant passages, or the lubricant passages.
Inspect the gasket surface of the cylinder head for distortion. Refer to Specifications, "Cylinder Head" for more information.
Illustration 1 g03005897
Typical example
Inspect dowel (5) and dowel (6) for damage. If necessary, replace the dowels in the cylinder block.
Install Tooling (D) to the cylinder block. Refer to Illustration 1.
Align cylinder head gasket (4) with Tooling (D) and with dowel (5) and dowel (6). Install the cylinder head gasket onto the cylinder block.
Illustration 2 g03005660
Use a suitable lifting device to lift the cylinder head. The weight of the cylinder head is approximately 30 kg (66 lb). Note: Use a spreader bar during the lifting operation in order to distribute the weight of the cylinder head.
Use Tooling (D) to align cylinder head (3) with the cylinder block. Install the cylinder head to the cylinder block. Note: Ensure that the cylinder head is correctly positioned onto dowels.
Illustration 3 g03005656
Illustration 4 g03005937
Clean Torx bolts (1) and Torx bolts (2). Follow Steps 8.a and 8.b for the procedure to inspect the Torx bolts.
Check the length of the Torx bolts (1) and Torx bolts (2).
Use Tooling (E) in order to check the threads of the Torx bolts. Refer to Illustration 4. Replace any Torx bolts that show visual reduction in the diameter of the thread over length (Y).
Lubricate the threads and the shoulder of Torx bolts (1) and Torx bolts (2) with clean engine oil.
Install Torx bolts (1) and Torx bolts (2) to cylinder head (3).
Remove Tooling (D).
Install remaining Torx bolts (1) to cylinder head (3).
Illustration 5 g03005658
Sequence for tightening the bolts for the cylinder head
Use Tooling (A) in order to tighten Torx bolts (2) to a torque of 130 N m (96 lb ft) in the sequence that is shown in Illustration 5.
Use Tooling (B) in order to tighten Torx bolt (1) to a torque of 65 N m (48 lb ft) in the sequence that is shown in Illustration 5.
Illustration 6 g03005916
Use Tooling (A), Tooling (B), and Tooling (C) in order to turn Torx bolts (1) and Torx bolts (2) through an additional angle in the sequence that is shown in Illustration 5. Turn Torx bolts (2) through 90 degrees.Turn Torx bolts (1) through 90 degrees.
Illustration 7 g03017298
Use Tooling (A), Tooling (B), and Tooling (C) in order to turn Torx bolts (1) and Torx bolts (2) through an additional angle in the sequence that is shown in Illustration 5. Turn Torx bolts (2) through 70 degrees.Turn Torx bolts (1) through 60 degrees.
Install the injectors. Refer to Disassembly and Assembly, "Injector - Install" for the correct procedure.
Install the glow plugs. Refer to Disassembly and Assembly, "Glow Plugs - Remove and Install" for the correct procedure.
Install the rocker shaft assembly and the pushrods. Refer to Disassembly and Assembly Manual, "Rocker Shaft and Pushrod - Remove" for the correct procedure.
Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install" for the correct procedure.
If necessary, install the water temperature regulator housing to the cylinder head. Refer to Disassembly and Assembly, "Water Temperature Regulator Housing - Remove and Install" for the correct procedure.
Connect the upper radiator hose to the water temperature regulator housing .
Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct filling procedure.
If necessary, fill the engine oil pan to the correct level. Refer to Operation and Maintenance Manual, "Engine Oil Level - Check".