5033030 JOHNSON CONNECTOR

Table 1
Required Tools
Tool Part Number Part Description Qty
A 9S-9082 Engine Turning Tool 1 Start By:
Remove the cylinder head.
Remove the piston cooling jets.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01149594
Use Tooling (A) to rotate the crankshaft until the piston is at the bottom center.
Remove the carbon ridge from the top inside surface of the cylinder liner.
Inspect the connecting rod and connecting rod cap for the proper identification mark. The connecting rod and the connecting rod cap should have an etched number on the side. The number should match the cylinder number. Mark the connecting rod and the connecting rod cap, if necessary. Note: Do not stamp the connecting rod assembly. Stamping or punching the connecting rod assembly could cause the connecting rod to fracture.
Remove bolts (1) and connecting rod bearing cap (2).
Illustration 2 g01149595
Remove piston (3) and the connecting rod from the cylinder liner. Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A 9S-9082 Engine Turning Tool 1
B 5P-3526(1) Piston Ring Compressor 1
200-3914(2) Piston Ring Compressor 1
C 8T-3052 Degree Wheel 1
(1) For use with 137 mm (5.4 inch) bores.
(2) For use with 145 mm (5.7 inch) bores.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Install the connecting rod bearings dry when clearance checks are performed. Refer to Disassembly and Assembly, "Bearing Clearance - Check". Apply clean engine oil on the connecting rod bearings for final assembly.
Apply clean engine oil to the cylinder liner bore, to the piston rings, and to the outer surface of the piston. Note: Ensure that the connecting rod and pistons are installed in the correct cylinder.
Illustration 3 g01149650
Use Tooling (A) to rotate the crankshaft until the connecting rod journal is at the bottom center.
Use Tooling (B) to install piston (3) and the connecting rod in the cylinder liner. Note: Install the connecting rod so that the bearing tab is located on the opposite side of the piston cooling jet.
Install the upper connecting rod bearing in the connecting rod. Note: Ensure that the connecting rod bearing is installed so that the bearing tab fits into the notch in the connecting rod.
Pull the connecting rod onto the crankshaft journal.
Install the lower connecting rod bearing in the connecting rod bearing cap. Note: Ensure that the connecting rod bearing is installed so that the bearing tab fits into the notch in the connecting rod.
Illustration 4 g01149651
Position connecting rod bearing cap (2) on the connecting rod. Note: Ensure that the number on the side of the connecting rod bearing cap is on the same side as the number on the connecting rod. The bearing tabs of the connecting rod bearing cap and the connecting rod are located on the side opposite of the piston cooling jet.
Lubricate the threads of bolts (1) with clean engine oil. Install the bolts.
Tighten bolts (1), as follows:
Tighten Bolt (A) and Bolt (C) to a torque of 70 4 N m (52 3 lb ft).
Tighten Bolt (B) and Bolt (D) to a torque of 70 4 N m (52 3 lb ft).
Turn Bolt (B) and Bolt (D) for an additional 60 5 degrees (1/6 turn). Note: If Tooling (C) is not used, place an index mark on each bolt.
Tighten Bolt (A) and Bolt (C) again to a torque of 70 4 N m (52 3 lb ft).
Turn Bolt (A) and Bolt (C) for an additional 60 5 degrees (1/6 turn). Note: If Tooling (C) is not used, place an index mark on each bolt.
Rotate the crankshaft in order to ensure that the crankshaft turns freely. End By:
Install the piston cooling jets.
Install the cylinder head.