0384530 JOHNSON CARBURETOR ASSY

Start By:a. remove space platesb. remove piston cooling jets. 1. If necessary, remove the cover from the front right side of the flywheel housing and use Tool (A) to turn the engine flywheel until all four of bolts (1) can be removed.2. Remove bolts (1) and bearing cap (2) from the connecting rod. 3. Push the piston assembly and the connecting rod up until the piston rings are clear of the cylinder liner. Remove piston assembly (3) and the connecting rod. Put identification on each piston as to its location for correct installation and alignment. Keep each bearing cap with its connecting rod. 4. Use Tool (B) and remove two retaining rings (4) that hold piston pin (5) in position. Remove pin (5) and remove piston assembly (3) from connecting rod (6).5. Remove the bearings from the bearing cap and connecting rod (6). 6. Use Tool (C) to remove piston rings (7) from piston assembly (3). 7. Remove crown (11) from skirt (12). If necessary, remove bearings (9).8. Check the condition of spring pins (10) in the piston skirt and replace if necessary.Install Piston & Connecting Rod Assemblies
1. Place the piston skirt over the piston crown in its original position.2. Clean the ring grooves in the piston.
Typical Example3. Use Tool (A) to install the oil ring on piston (1). Make sure the oil ring spring ends are 180 degrees apart from the ring end gap.4. Use Tool (A) to install the two compression rings on piston (1). Make sure the sides with the "UP" marks are toward the top of the piston and all three ring end gaps are 120 degrees apart after installation. 5. Put clean engine oil on pin (3), the pin bearing in rod (2) and the pin bore in piston (1). Put rod (2) in position in piston (1) and install pin (3). Use Tool (B) to install rings (4) on each side of pin (3).6. Install the upper half of the connecting rod bearing in the connecting rod and put clean engine oil on it. Make sure the tab on the back of the bearing fits in the groove of the rod. 7. Put clean engine oil on the piston rings and cylinder liner bore. Use Tool (D) to put the piston rings under compression and install the pistons and connecting rods in the cylinder.
Make sure the piston assembly is installed with the chamfer side (X) of the connecting rod bore next to the crankshaft thrust surface. The side with the square shoulder (Y) for the connecting rod bearing bore, must be next to the other connecting rod on the same crankshaft journal.
8. Install the lower half of the connecting rod bearing in cap (5) and put clean engine oil on it. Make sure the tab on the back of the bearing fits in the groove of the cap.9. See the topic "Install Connecting Rod Bearings" for the procedure to install the connecting rod caps and to check the bearing clearance.10. Check the side clearance between two connecting rods on the same crankshaft journal. The clearance must be 0.85 0.23 mm (.0335 .0091 in).End By:a. install piston cooling jetsb. install spacer plates