5006592 JOHNSON Service Manual - English

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     207-5034 (1)     Stud Tensioner Tool Gp     1    
301-5215 (2) Stud Tensioner Tool Gp     1    
B     8T-0820     Hydraulic Pressure Gauge     1    
3S-6224 (3) Electric Hydraulic Pump     1    
8S-8033 (3) Electric Hydraulic Pump     1    
9U-6600 (3) Hand Hydraulic Pump     1    
8T-3035 Hydraulic Line     1    
C     126-6918 (4)
or
126-6919 (5)     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 ) Operating pressure is 40000 1520 kPa (5800 220 psi).
( 2 ) Operating pressure is 125000 4920 kPa (18130 715 psi).
( 3 ) There are three pumps that are listed in the tool chart. Any one of the pumps may be used for this procedure.
( 4 ) Use with V-engines
( 5 ) Use with In-line engines
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Refer to Disassembly and Assembly, "General Information (Reference Material)" for more information.Note: Tooling (D) provides all the protective covers and plugs for one cylinder. Use these protective covers in order 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 of the cylinder liner and top of the piston. Apply clean engine oil to the inside of 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 g01310648
Cuffed liner
Illustration 2 g00639831
Cuffed linerNote: The following Steps are for cuffed liners and for noncooled liners.
Put a new O-ring seal on both sides of the seal plates at Locations (W) and (X). Put new O-ring seals on the seal retainers at Location (Z). Install seal plate (13), seal plate (11), and the seal retainers. Put new O-ring seals on both sides of the adapter at Location (Y) on the seal plates.
Put combustion gasket (12) in position on top of the cylinder liner.
Illustration 3 g01310649
Attach Tooling (C) and a suitable lifting device to cylinder head (10). The weight of cylinder head (10) is approximately 204 kg (450 lb).
Carefully lower cylinder head (10) onto the cylinder head studs. While the cylinder head is being lowered, reach through the side opening and hold rod assembly (4) so that the rod assembly does not interfere with the cylinder head assembly.
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