5005027 JOHNSON ENGINE COVER Assy

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1U-8221 Lifting Sling 2 Start By:
Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Remove" for the correct procedure.
Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove" for the correct procedure.
Remove the crankshaft rear seal. Refer to Disassembly and Assembly, "Crankshaft Rear Seal - Remove" for the correct procedure.
If necessary, remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove" for the correct procedure.
If necessary, remove the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Remove" for the correct procedure.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
The engine should be mounted on a suitable stand and placed in the inverted position.
If the cylinder head, the pistons and the connecting rods have not been removed already, remove the connecting rod bearings. Refer to Disassembly and Assembly, "Connecting Rod Bearings - Remove" for the correct procedure.
Ensure that the main bearing caps are marked for the location and orientation.
Illustration 1 g02724705
If necessary, follow Step 4.a through Step 4.c in order to remove the cross over tube assembly from the cylinder block.
Remove bolts (3) from tube assembly (1).
Remove tube assembly (1) from the cylinder block.
Remove gaskets (2) (not shown).
Illustration 2 g02725174
In order to remove the number seven main bearing, the removal of the bridge piece will be required. Follow Step 5.a through Step 5.b in order to remove the bridge piece.
Remove allen head bolts (4) from bridge piece (5).
Remove bridge piece (5) from the cylinder block.
Illustration 3 g02725202
Illustration 4 g02725203
Remove bolts (6) and main bearing caps (7) from the cylinder block.
Remove lower main bearing shells (8) from main bearing caps (7). Keep the lower main bearing shells with the respective main bearing caps. Note: The lower main bearing shells are plain bearings that have no oil holes.
Illustration 5 g02725175
For number six main bearing, remove two thrust washers (9) from the cylinder block. In order to remove thrust washers (9), rotate the crankshaft in the correct direction. If necessary, push the crankshaft toward the front of the engine while you rotate the crankshaft, in order to aid removal. If necessary, push the crankshaft toward the rear of the engine while you rotate the crankshaft, in order to aid removal. Note: The thrust washers have a locating tab at one end.
Illustration 6 g02725176
Attach Tooling (A) and a suitable lifting device to crankshaft (10). Lift crankshaft (10) out of the cylinder block. The weight of the crankshaft is approximately 61 kg (134 lb). Note: Do not damage any of the finished surfaces on the crankshaft. When the crankshaft is removed from the engine, the crankshaft must be supported on a suitable stand in order to prevent damage to the crankshaft timing ring.
Illustration 7 g02725177
Remove upper main bearing shells (11) from the cylinder block. Keep the upper main bearing shells with the respective main bearing caps. Note: The upper main bearing shells have a groove and two oil holes.
If necessary, remove the crankshaft gear. Refer to Disassembly and Assembly, "Crankshaft Gear - Remove and Install" for the correct procedure.