0211638 JOHNSON OWNERS'S MANUAL

(1) Steam clean the engine. Obtain an SOS sample; be sure the oil is hot and well mixed before you take the sample. Disconnect the batteries. (2) Disconnect the wires from glow plugs (1). Use 5P0127 or 9S2573 Socket to remove the glow plugs. Disconnect the fuel line assemblies from the valve bodies. Install 2F2990 Plugs and 5F2807 Caps on the fuel line connections to keep them free of dirt.(3) Remove nut (2) that holds each body assembly in position. Remove each body assembly (3) from the precombustion chamber. Remove nozzle (4) from each body. Install the new nozzle on each body; tighten finger tight only. Install the seals on the body assemblies and then install the body assemblies in the precombustion chambers.(4) Install the nuts that hold the body assemblies in the precombustion chambers. Tighten each nut to a torque of 142 7 N m (105 5 lb.ft.). Install the seal assemblies on the body assemblies.(5) Connect the fuel injection lines to the body assemblies. Use 5P0144 Socket and a torque wrench to tighten the nuts to a torque of 40 7 N m (30 5 lb.ft.). Be sure the fuel line clamps are tight.(6) Put high temperature anti-seize compound on the glow plug threads. Place the glow plugs in position in the precombustion chambers. Use 5P0127 or 9S2573 Socket to tighten to a torque of 13.6 2.8 N m (120 24 lb.in.). (7) Remove the bolts that hold glow plug wiring harness (6) to the valve cover and remove the harness. Remove the bolt and clamp from breather assembly (5) and remove the breather. Remove the valve cover and gasket.(8) Put No. 1 piston at top center (TC) on the compression stroke by turning the flywheel clockwise (opposite the direction of engine rotation) approximately 30°. This will ensure all play is removed from the timing gears when the engine is at TC. Remove plug (7) and turn the flywheel counterclockwise until a 3/8"-16 NC bolt can be installed through the hole in the flywheel housing. The No. 1 piston is at TC. If the flywheel is turned beyond the point at which the 3/8"-16 NC bolt can be installed, turn the flywheel clockwise a minimum of 30° before turning it counterclockwise toward alignment again.(9) Look at the valves of cylinder 1 to see if No. 1 piston is on the compression stroke. If cylinder 1 is on the compression stroke, the valves will be closed. (You should be able to move the rocker arms up and down by hand.) If No. 1 piston is not on the compression stroke, remove the bolt and turn the flywheel 360° counterclockwise. Install the 3/8"-16 NC bolt as before. The No. 1 piston is now at TC on the compression stroke. (10) Make an adjustment to the valve clearance on the intake valves for cylinders 1, 2 and 4. Make an adjustment to the valve clearance on the exhaust valves for cylinders 1, 3 and 5.(11) Turn the flywheel 360° in the direction of engine rotation. This will put No. 6 piston at TC on the compression stroke.(12) Make an adjustment to the valve clearance on the intake valves for cylinders 3, 5 and 6. Make an adjustment to the valve clearance on the exhaust valves for cylinders 2, 4 and 6.(13) After the valve adjustments are correct, tighten the nuts for the valve adjustment screws to 28 4 N m (22 3 lb.ft.). Remove the timing bolt from the flywheel when all the adjustments to the valve clearances have been made. (14) Put contact cement on the face of the valve cover and the top side of the valve cover gasket. Put the valve cover gasket in position in the valve cover. Position the valve cover on the cylinder head and install the bolts that hold it in place. Tighten the bolts to a torque of 11 3 N m (8 2 lb.ft.).(15) Install glow plug wiring harness (9) and connect the wires to the glow plugs. Install seal and breather assembly (8).(16) Drain the cooling system to a level below the water temperature regulator housing. Disconnect the radiator hose from the top of the water temperature regulator housing. Remove four bolts (10) and remove the water temperature regulator housing. Remove the regulator from the housing. Put the temperature regulator and gaskets in position. Install the water temperature regulator housing on the cylinder head.(17) Connect the radiator hose to the top of the housing. Fill the cooling system to the correct level. Connect the batteries and start the engine. It may be necessary to prime the fuel system if the engine fails to start.(18) Inspect for leaks. Stop the engine and allow the oil to drain. Check to see that the oil and coolant are at their correct levels.