0284482 JOHNSON ENGINE COVER ASSY., 100 models

START BY:a. remove hoodb. remove fan guard1. Drain the coolant from the cooling system. 2. Loosen two hose clamps (1), and disconnect hose (3) and tube (2) as a unit from the radiator. Turn inlet tube (2) in the lower hose to provide clearance when the radiator and guard are removed.
Always wear goggles when working on air conditioning systems. The system is under pressure at all times, engine running or not. Escaping Freon-12 (C C12 F2 Dichloro Difluoro Methane) can cause freezing of human flesh.Do not smoke while working on air conditioning systems. Inhaling Freon-12 through any smoking material, although not toxic or flammable, can generate phosgene gas and cause violent illness. Also, heat must never be applied to a charged system. See Air Conditioning And Heating Service Manual, Form No. SENR7454, for more information on removal and installation of lines and refrigerant from the system.
3. Loosen coupling (4), and disconnect hose assembly (5) from the coupling (if equipped with air conditioning). 4. Disconnect tube assembly (7) and (8) from tees (6). 5. Loosen the coupling, and disconnect tube assembly (10) from the coupling (if equipped with air conditioning).6. Remove two bolts (11) that connect bracket (9) to the radiator group. Remove bracket (9) and dryer (12) as a unit from the radiator group. 7. Remove clip assembly (15), and disconnect connector (13) that holds the wire assembly together.8. Remove the bolt that holds clips (14) and the wiring harnesses to the rear frame. 9. Remove plunger (dipstick) (16) and strainer (17) from the tube assembly. 10. Remove two hose clamps (18) that connect hose (19) to the tube assembly.11. Remove two bolts (20) and the spacers that hold the radiator guard to the rear frame on the right side of the machine.12. Disconnect battery cable (21) from the battery. 13. Remove bolt (26) that holds clip (25) and wiring harness (24) to the fuel tank.14. Remove bolt (23) that holds the clip and wiring harness to the fuel level sender.15. Remove nut (22), and disconnect wiring harness (24) from the fuel level sender. 16. Remove the nut, and disconnect cable assembly (29) from the frame.17. Disconnect battery cable (28) from the battery.18. Remove two bolts (27) and the spacers that hold the radiator guard to the rear frame on the left hand side of the machine. 19. Fasten tooling (A) and a hoist to radiator group (30) as shown. 20. Remove bolt (32) that holds radiator guard to the rear frame on the right hand side of the machine. Remove clips (31) that hold the wiring harnesses and spacer (33).21. Remove the other bolt and spacer that holds the radiator guard to the rear frame on the left hand side of the machine.
Do not damage the tube assemblies that were disconnected in Step 4 when the radiator and guard are removed.
22. Remove radiator and guard assembly (30) as a unit from the machine. The weight of the radiator and guard assembly as a unit is approximately 240 kg (530 lb.). The following steps are for installation of the radiator guard.23. Fasten tooling (A) and a hoist to the radiator group as shown.
Do not damage the two tube assemblies that were disconnected in Step 4.
24. Carefully put radiator and guard assembly (30) as a unit in position on the machine as shown. Do not damage the two tube assemblies to the oil cooler.25. Put spacer (33) and clips (31) that hold the wiring harnesses in position. Install bolt (32) that holds them and the radiator guard to the rear frame on the right hand side of the machine.26. Put the other spacer in position, and install the bolt that holds the spacer and the raditor guard to the rear frame on the left hand side of the machine.27. Put wiring harness (24) in position on the fuel level sender, and install the nut that holds it.28. Install bolt (23) that holds the clip and wiring harness (24) to the fuel level sender.29. Install bolt (26) that holds the clip and wiring harness (24) to the fuel tank.30. Install the two spacers and bolts (27) that hold the radiator guard to the rear frame on the left hand side of the machine.31. Put cable assembly (29) in position, and install the nut that holds it in place.32. Connect battery cable (28) to the battery.33. Install the other two spacers and bolts (20) that hold the radiator guard to the rear frame on the right hand side of the machine.34. Install two hose clamps (18) that connect hose (19) to the tube assembly.35. Connect battery cable (21) to the battery.36. Install strainer (17) and plunger (dipstick) (16) in the tube assembly.37. Put wire assembly connector (13) together, and install clip assembly (15) that holds it together.38. Put the wiring harness and clips (14) in position on the rear frame. Install the bolts that holds them in place.39. Put dryer (12) and bracket (9) in position as a unit, and install the two bolts that