0349732 JOHNSON FUEL BLADDER (Tank)

Table 1
Required Tools
Tool Part Number Part Description Qty
A 9S-9082 Engine Turning Tool 1
B 1P-1861 Retaining Ring Pliers 1
C 6V-4020 Piston Ring Expander 1
D 5P-8639 Hydraulic Press 1
5P-9725 Hydraulic Cylinder 1
8F-0024 Hose Assembly 1
1P-2375 Connecting Coupler 1
1P-2376 Connecting Coupler 1
1U-5230 Hand Hydraulic Pump 1
5P-8640 Bar Clamp 1
E 6V-3042 Adapter 1
F 6V-3043 Spacer 1
G 5P-8649 Adapter 1 Start By:
Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove".
Remove the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets - Remove and Install".
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Use Tooling (A) to turn the engine in order to access the bolts in the connecting rod cap.
Mark the cylinder number on each connecting rod and the corresponding connecting rod cap. Note: The front of the engine is opposite the flywheel end. The No. 1 cylinder is at the front of the engine on the right side. The No. 2 cylinder is on the left side.
Illustration 1 g00582418
Remove bolts (1) and connecting rod cap (2) from the connecting rod.
Remove the bearings from connecting rod cap (2) and the connecting rod.
Illustration 2 g00582419
Push piston (3) out of the cylinder liner until the piston rings are completely out of the cylinder liner.
Remove the piston and connecting rod assembly.
Illustration 3 g01051820
Use Tooling (B) to remove the retaining rings that hold piston pin (4).
Remove piston pin (4).
Remove piston (3) from connecting rod (5).
Illustration 4 g00582421
Use Tooling (C) to remove piston rings (6) from piston (3).
Clean the piston ring grooves with an acceptable ring groove tool. Refer to Guideline For Reusable Parts, SEBF8059, "Procedure To Clean And Inspect 3500 Series Engine Pistons" for the correct procedure for cleaning the pistons.
Raise the temperature of the connecting rod. Note: Do not use a direct flame in order to heat the connecting rod.
Illustration 5 g01089121
Place Tooling (F) in the base plate of Tooling (D). Place the connecting rod on the base plate.
Place the piston pin bearing in the center of the port assembly on Tooling (D). Install pin (9) in the center of the bore for the piston pin.
Install Tooling (G). Align the hole in the adapter with the hole that is in the base plate of Tooling (D).
Install the bar clamp and clamp pin (10). Note: The old bearing is pushed out while the new bearing is installed.
Position Tooling (E) with the tapered side facing downward. The piston pin bearing joint must be aligned with the hole in the adapter and the hole in the base plate of Tooling (D).
Place pusher (7) on adapter (11).
Use Tooling (D) to push new piston pin bearing (8) into the connecting rod until adapter (11) makes contact with the connecting rod.
Remove the connecting rod and the old piston pin bearing from Tooling (D).
After the piston pin bearing is installed, measure the diameter of the bearing bore. The correct diameter is 70.000 0.008 mm (2.7559 0.0003 inch).
Refer to Special Instruction, SEHS7295, "Use Of Piston Pin Bearing Removal And Installation Tools" for more information.