0337908 JOHNSON PLUG, Shift rod hole, 90/115 Jet models

2. Remove fuel filter (1). Remove nut (2) and push the bolt through the timing gear cover.3. Remove clamps (3) from the water sleeves in each cylinder head. 4. Use tool (A) to push water sleeves (4) into the timing gear cover. 5. Remove two head bolts and install two 1/2"-13 NC x 3 in. guide bolts (6). Remove the remainder of head bolts (5) and lifting bracket (7) from the cylinder head.
Make sure the fuel injection nozzles are removed before the cylinder heads are removed. The fuel injection nozzles go through the cylinder heads and the nozzle tips can be broken off if the nozzles are not removed from the heads.
6. Fasten tooling (B) and a hoist to cylinder head (8) and remove the cylinder head. Weight is approximately 39 kg (85 lb.).Install Cylinder Heads
1. Clean the contact surfaces of each cylinder head and the cylinder block. Make sure the surfaces are clean and dry. Install a new gasket for each cylinder head. 2. Clean bore (1) in each cylinder head for the water sleeve. Inspect the O-ring seal on each water sleeve and install new O-ring seals if necessary. Put oil on the O-ring seals.3. Fasten tooling (A) and a hoist to the cylinder head. 4. Install two 1/2"-13 NC x 3 in. guide bolts (2) in the cylinder block. Put the cylinder heads in position on the cylinder block.5. Put engine oil on the bolt threads and install the bolts that hold the cylinder heads in place. Tighten the bolts in the cylinder heads according to the following HEAD BOLT CHART. 6. Install lifting bracket (3). 7. Use tool (B) to push water sleeves (4) into the cylinder heads. 8. Install clamps (5) on the water sleeves. 9. Push the bolt through the timing gear cover and install nut (6) on the bolt.10. Install fuel filter (7).11. Install the alternator bracket on the right cylinder head and the heat shield on the right side of the engine.12. Fill the cooling system with coolant to the correct level.end by:a) install alternator (right cylinder head only)b) install fuel injection nozzlesc) install rocker shafts and push rodsd) install air inlet manifolde) install exhaust manifoldsDisassemble Cylinder Heads
start by:a) remove cylinder heads 1. Fasten a hoist and put the cylinder head in position on tool (A). Use adapter plates (1) from tooling (A) to hold the head in place. 2. Put the valve spring under compression with tool (C).3. Remove the locks from the valves. 4. Remove tool (C), retainer, spring, washer and valve from the cylinder head. Put identification on the valve as to its location in the cylinder head.5. Check the valve spring force with tool (B). For the correct spring force, see the subject VALVES in SPECIFICATIONS.6. Do Steps 2 through 5 for the remainder of the valves. 7. Remove the valve seat inserts with tooling (D). The valve guides are part of the cylinder head. Measure the bore in each valve guide 19.0 mm (.75 in.) from the outside edge on both ends of each valve guide. The bore must be 9.512 0.013 mm (.3745 .0005 in.). The maximum permissible bore is 9.550 mm (.376 in.). Valve guides worn more than the maximum specification can be made to the original size by knurling. For more information on valves and valve springs see GUIDELINE FOR REUSABLE PARTS VALVES AND VALVE SPRINGS, Form No. SEBF8002-01 and VALVES AND VALVE SPRINGS SPECIFICATIONS Form No. SEBF8034-02.Assemble Cylinder Heads
1. Clean and remove burrs and all foreign material from the valve seat bores. 2. Lower the temperature of the valve seat inserts and install them with tooling (A).
Do not make the diameter of the extractor (part of tooling A) in valve seat insert larger when the insert is installed in the cylinder head.
3. Grind the valve seat inserts according to the dimensions given in SPECIFICATIONS. 4. Put clean engine oil on the valve stem. Install the valve, washer (3), spring (2) and retainer (1) in the cylinder head. 5. Put the valve spring under compression with tool (C).6. Install the locks on the valve stem with tool (B).
Make sure locks (4) are in their correct position on the valve. The locks can be thrown from the valve when tool (C) is released if the locks are not in their correct position on the valve.
7. Remove tool (C) and hit the valve with a rubber hammer to be sure the locks are in their correct position.8. Do Steps 4 through 7 for the remainder of the valves.end by:a) install cylinder heads