0211416 JOHNSON OWNERS MAN., Ev.

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Guide Studs
M16 by 115mm 2
B 8T-3052 Degree Wheel 1
C - Delphi Lockheed Rubber Grease 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the wiring harness assembly is correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness convoluting.
Thoroughly clean the gasket surfaces of the cylinder head and the cylinder block. Do not damage the gasket surfaces of the cylinder head of 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. If the gasket surface of the cylinder head is distorted beyond maximum permitted limits, replace the cylinder head.
Illustration 1 g06194089
Inspect dowels (22) in Positions (Y) for damage. If necessary, replace the dowels in the cylinder block.
Install Tooling (A) to the cylinder block in positions (X).
Align cylinder head gasket (21) with dowels (22). Install the cylinder head gasket onto the cylinder block.
Use a suitable lifting device to lift cylinder head. The weight of the cylinder head is approximately 66 kg (146 lb).Note: A spreader bar must be used to distribute the weight of the cylinder head during the lifting operation.
Use Tooling (A) to align the cylinder head with the cylinder block. Install the cylinder head to the cylinder block.Note: Ensure that the cylinder head is correctly positioned on dowels (22).
Remove Tooling (A) from the cylinder block.
Illustration 2 g06194090
Clean bolts (20). Use a straight edge to check the threads of the bolts. Refer to Illustration 2. Replace any bolts that show visual reduction in the diameter of the thread over Length (Y).
Lubricate the threads and the shoulder of bolts (20) with clean engine oil.
Illustration 3 g06194128
Sequence for tightening the bolts for the cylinder head
Install bolts (33) to cylinder head (34).
Tighten the bolts to a torque of 50 N m (37 lb ft) in the numerical sequence. Refer to Illustration 3.
Tighten the bolts to a torque of 100 N m (74 lb ft) in the numerical sequence. Refer to Illustration 3.
Use Tooling (B) to turn the bolts through an additional 225 degrees in the numerical sequence. Refer to Illustration 3.
Illustration 4 g06191879
Use Tooling (C) to lubricate the O-ring seal. Install new O-ring seal (14) to bypass tube (15).
Install bolts (17) to bypass tube (15).
Position gasket (16) (not shown) onto bolts (17).
Install the bypass tube in the cylinder head. Tighten bolts (17) to a torque of 22 N m (195 lb in).
Illustration 5 g06191781
Illustration 6 g06191747
Connect harness assembly (11) to coolant temperature sensor (12). Slide locking tab (13) into the locked position.Note: Ensure that the cable straps meet Original Equipment Manufactures (OEM) specification.
Connect harness assembly (10) to inlet air temperature sensor (6). Slide locking tab (5) into the locked position.
Connect harness assembly (9) to boost pressure sensor (7). Slide locking tab (8) into the locked position.
Position the harness assembly onto the cylinder head. Use new cable straps to secure the harness assembly to the cylinder head. Ensure that cable straps meet the OEM specification. Ensure that the harness assembly is not strained.Note: Ensure that the harness assembly is clear of other engine components.
Illustration 7 g06191682
Install bolts (2) to tube assembly (3).
Position gasket (4) (not shown) onto bolts (2).
Position tube assembly (3) onto the cylinder head. Tighten bolts (2) to a torque of 22 N m (195 lb in)
Install the hose (not shown) to the coolant outlet on tube assembly (3).
If necessary, install water temperature regulator housing (1) 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 water temperature regulator housing (1) on the cylinder head.
If necessary, fill the engine oil pan to the correct level that is indicated on the engine oil level gauge. Refer to Operation and Maintenance Manual, "Engine Oil Level - Check" for the corr