0384697 JOHNSON CAM FOLLOWER

Start By:a. remove cylinder head assemblyb. remove engine balancer group (3114 Engines)c. remove oil pump (3116 Engines)d. remove piston cooling tubes 1. Check the connecting rods and caps for their identification and location in the engine. The connecting rods are to be marked (only by etching) with the number of the cylinder in which they are used. Rods and caps are to be marked on the same side of the rod in relation to the bearing retainer notch.2. Remove rod cap nuts (1) and rod bearing cap (2) from the connecting rod. Remove the lower half of the bearing from the rod bearing cap.
To protect the crankshaft from the threaded portion of the connecting rod bolts, cut short pieces of rubber hose, and install them over the threaded portion of the bolts as shown in Photo C20235P1.
3. Carefully remove the piston and connecting rod from the cylinder block. Remove the upper half of the bearing from the connecting rod.4. Remove the remainder of the pistons and connecting rods as in Steps 1 through 3. The following steps are for the installation of the pistons and connecting rod assemblies. 5. Position the piston ring end gaps 120 degrees apart. Install Tool (A) on the piston as shown.6. Be sure the short pieces of rubber hose are installed on the connecting rod bolts. Install the connecting rod and piston group with the rod forging part number facing to the rear of the engine. The rear of the engine is the flywheel end. Thoroughly lubricate the piston crown, piston skirt and the cylinder bore with clean engine oil just prior to installation of the piston group in the cylinder block.7. With the number one crankshaft throw at bottom center, carefully install the piston and connecting rod assembly in the cylinder block. 8. Put the connecting rod in alignment with the crankshaft. Using a rubber mallet, tap the piston into the cylinder bore until Tool (A) comes off of the piston.9. Before the connecting rod comes in contact with the crankshaft, install the upper half of the rod bearing. Be sure the bearing tab engages with the groove in the connecting rod.10. Apply clean engine oil on the upper rod bearing. Continue tapping the piston down, guiding the connecting rod onto the crankshaft.11. Position the lower half of the rod bearing in the corresponding numbered rod bearing cap. Be sure the bearing tab engages with the groove in the rod bearing cap.13. Put clean engine oil on the lower rod bearing surface. Install the rod bearing cap on the connecting rod with the number on the bearing cap on the same side and same number as on the connecting rod.14. Tighten the connecting rod bolts as follows: a. Put clean engine oil on the bolt threads, and all surfaces that make contact between the bolts and cap.b. Tighten each rod cap nut (1) to a torque of 54 7 N m (40 5 lb ft).c. Put a reference mark on each rod cap nut; then tighten each nut an 1/6 additional 60 5 degrees ( turn).15. Install the remainder of the piston and connecting rod assemblies as in Steps 5 through 14c.End By:a. install piston cooling tubesb. remove oil pump (3116 Engines)c. remove engine balancer group (3114 Engines)d. Install cylinder head assemblyDisassemble & Assemble Pistons & Connecting Rod Assemblies
Start By:a. remove pistons and connecting rod assemblies 1. Using suitable retaining ring pliers, remove two pin retainers (5). Remove piston pin (7). Separate piston crown assembly (1) and piston skirt (6), as a unit, from connecting rod assembly (8). Separate the piston crown from the piston skirt. 2. Using Tool (A), remove top piston ring (2), intermediate piston ring (3) and oil piston ring (4) from the crown.3. Using Tooling (B), remove bearing (9) from connecting rod (8). The following steps are for the assembly of the pistons and connecting rod assemblies. For specifications of pin bores and clearances between the ends of the piston rings, see the topic "Pistons And Rings" in the 3114 & 3116 Diesel Truck Engines Specifications module, Form No. SENR6436.4. Be sure all parts of the piston and connecting rod assembly are thoroughly clean. Be sure the piston ring grooves in the crown are thoroughly clean.5. Using Tool (A), install oil piston ring (4) on the crown. Install the ring so the end gap in the spring is 180 degrees away from the end gap in the ring. The light green portion of the spring must be visible at the end gap of the ring.6. Using Tool (A), install intermediate piston ring (3) on the crown. The intermediate piston ring has the mark "UP-2". This mark must be facing toward the top of the piston (blue color strip to right of ring end gap).7. Using Tool (A), install top piston ring (2) on the crown. The top piston ring has the mark "UP-1". This mark must be facing toward the top of the piston (green color strip to right of ring end gap.8. Install bearing (9) in the connecting rod. Heat the connecting rod only around the area of the piston pin bore to a temperature of 175 to 260°C (347 to 500°F). Do not use a torch to heat the connecting rod. Using Tooling (B), install the bearing in the connecting rod. Install the bearing so the bearing joint is above the horizontal centerline of the piston pin bore 1/2 12.5 degree on either side.9. Put piston crown (1) in position in piston skirt (6). Put clean engine oil on piston pin (7). Put the piston crown and piston skirt in position on the connecting rod. Using suitable retaining ring pliers, install two pin retainers (5). Prior to installing the piston and connecting rod assembly in the cylinder block, be sure the end gaps of the piston rings are 120 degrees apart.End By:a. install pistons and connecting rod assemblies