0383299 JOHNSON AMPLIFIER ASSEMBLY

1. Remove the piston from the cylinder liner that is to be removed. See REMOVE PISTONS.2. Turn the crankshaft so that the counterweights on the crankshaft are away from the bottom of the cylinder liner as shown. 3. Install tooling (A). Use tooling (A) to remove cylinder liner (1) from the block. 4. Remove filler band (2) and seals (3) from the cylinder liner.5. Do Steps 1 through 4 for the other cylinder liners if necessary.Install Cylinder Liners
1. Make sure the bore of the engine block and the cylinder liner are clean. Install cylinder liner (1), without the filler band or seals, in the engine block. 2. Install the spacer plate gasket and spacer plate (2).3. Install tooling (A) around the cylinder liner as shown. Tighten the four bolts from tooling (A) evenly in four steps: 14 N m (10 lb.ft.), 35 N m (25 lb.ft.), 70 N m (50 lb.ft.) and then to 95 N m (70 lb.ft.).4. Use two bolts from the cylinder head to hold tooling (B) in position over the cylinder liner. Be sure the crossbar [part of tooling (B)] is in position at the center of the cylinder liner. Tighten the bolts that hold tooling (B) in place evenly in four steps: 7 N (5 lb.ft.), 20 N m (15 lb.ft.), 35 N m (25 lb.ft.) and then to 70 N m (50 lb.ft.).5. Check the distance from the bottom edge of crossbar to the top of the spacer plate. The distance on each end of the crossbar must be the same.6. Check the liner projection with tool (C) at four locations around the liner flange. Liner projection must be 0.025 to 0.152 mm (.001 to .006 in.). The difference between the four measurements on the same liner must not be more than 0.05 mm (.002 in.). The difference between average liner projection for liners next to each other must not be more than 0.05 mm (.002 in.). The maximum difference in the average projection of the cylinder liners under each cylinder head must not be more than 0.10 mm (.004 in.). If the liner projection changes too much from point to point around the liner, turn the liner to a new position in the bore. If the projection measurements are still not within specifications, move the liner to a different bore in the cylinder block and check the projection again.7. If a liner does not measure within the correct projection specifications, the projection can be changed with a counterbore operation to the top surface of the cylinder block. The counterbore depth must be in a range from a minimum of 0.76 mm (0.30 in.) to a maximum of 1.14 mm (.045 in.). Shims are available to then adjust the liner to the correct projection. See SPECIAL INSTRUCTION Form No. FMO55228-03 for procedure to use the 8S3140 Cylinder Block Counterboring Tool Arrangement. See CYLINDER LINER PROJECTION in TESTING AND ADJUSTING section of Service Manual to find shim thickness, part number and installation procedure.8. Put a mark on cylinder liner (1) and spacer plate (2) so the cylinder liner can be installed in the same position. Remove tooling (A) and (B). Remove cylinder liner (1). 9. Put liquid soap on seals (3), the grooves of the liner and on the bore in the block. Install seals (3) on the cylinder liner. Put filler band (4) in clean SAE 30 oil for a short moment. Install filler band (4) on the cylinder liner. After the filler band is installed on the cylinder liner, the cylinder liner must be installed immediately into the cylinder block. 10. Use tooling (D) to install cylinder liner (1) in the block. Make sure the mark on the cylinder liner is in alignment with the mark on the spacer plate.END BY:a) install pistons