0392022 JOHNSON PISTON, Std. 235

Table 1
Required Tools
Tool Part Number Part Description Qty
A 207-5034 Stud Tensioner Tool Gp 1
B 8T-0820 Hydraulic Pressure Gauge 1
3S-6224(1) Electric Hydraulic Pump 1
8S-8033(1) Electric Hydraulic Pump 1
9U-6600(1) Hand Hydraulic Pump 1
8T-3035 Hydraulic Line 1
C 126-6918(2)
or
126-6919(3) Cylinder Head Lifting Bracket 1
126-6920 Handle Rod 1
5D-1972 Bolt 2
D 229-3639 Overhaul Protection Gp 1
F 183-3424 Water and Temperature Resistant Grease 1
(1) There are three pumps that are listed in the tool chart. Any one of the pumps may be used for this procedure.
(2) Use with V-engines
(3) Use with In-line engines
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Tooling (D) provides all the protective covers and plugs for one cylinder. Use these protective covers to maximize the protection during these procedures.
Thoroughly clean the sealing surfaces on top of the cylinder block assembly.
Remove all debris from the inside the cylinder liner and top of the piston. Apply clean engine oil to the inside the cylinder liner.
Earlier engines may have RTV coating on the cylinder head studs. Remove all debris from the holes in the cylinder block. Thoroughly clean the cylinder head studs and the top surface of the cylinder block. Paint the cylinder head studs if the cylinder head studs were cleaned to the bare metal.
If the cylinder head studs were removed, use the following procedure to install the cylinder head studs:
Before installing the cylinder head studs, coat the lower half of the cylinder head studs with Tooling (F). Apply an extra bead of grease around the cylinder head studs at the base of the cylinder head studs on the face of the block. This will help ensure that the counterbore in the top of the block is full of grease.
Thoroughly clean the top of the cylinder block.
Install the cylinder head studs in the block and tighten to a torque of 100 20 N m (75 15 lb ft).
Coat the entire length of the cylinder head studs with Tooling (F) after the cylinder head studs are installed in the cylinder block.
Always install the seal plates after the cylinder liners are installed. Aluminum debris shaved from the plates by the cylinder liners will prevent the cylinder liners from sealing if the plates are installed first.
Illustration 1 g01299480
Cuffed liner
Note: The following Steps are for cuffed liners and for noncooled liners.
Put a new O-ring seal on both sides of seal plate (9) and seal plate (11). Put new O-ring seals on the seal adapters. Install the seal plates and the seal adapters.
Put combustion gasket (10) in position on top of the cylinder liner.
Attach Tooling (C) and a suitable lifting device to the cylinder head. The weight of the cylinder head is approximately 204 kg (450 lb).
Carefully lower the cylinder head onto the cylinder head studs.
Be sure that the cylinder head assembly is seated on the dowels and be sure that the seal plates and the O-ring seals are seated properly.
Install the nuts and the washers to hold the cylinder head. Tighten the nuts by hand.Note: Lubricate the washer face and the threads of the cylinder head studs with Tooling (F) before assembly.
Illustration 2 g01300860
Install Tooling (A) over the nuts, and attach Tooling (B) to Tooling (A).
Tighten collars (4) with a ratchet lever (1/2 inch drive). Loosen the collars for 1/4 turn.
Personal injury can result from oil under high pressure.DO NOT allow high pressure oil to contact skin.Wear appropriate protective equipment while working with high pressure oil systems.
Set Tooling (B) to achieve 40000 1520 kPa (5800 220 psi). When pressure is applied to Tooling (A), then place dowel handle (5) through the slot in each pedestal to tighten each cylinder head nut. Tighten the cylinder head nuts hand tight. Refer to Engine News , SEBD9741 , The Stud Tensioner Tool Groups for 3600, C280, and G3600 Engines Require Different Hydraulic Pressures.
Slowly release the hydraulic pressure from Tooling (B). Reset the pressure on Tooling (B) to achieve 40000 1520 kPa (5800 220 psi). When pressure is applied to Tooling (A), then place dowel handle (5) through the slot in each pedestal to tighten each cylinder head nut. Tighten the cylinder head nuts hand tight.
Slowly release the pressure from Tooling (B) for the final time.
Remove Tooling (A) from the cylinder head assembly, the cylinder head studs, and the nuts.