0438616 JOHNSON FUEL PUMP REPAIR KIT

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     439-3939     Link Bracket     2    
B     8T-5096     Dial Indicator Group     1    
C     4C-5590     Anti-Seize Compound     -    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the crankshaft main bearing tabs engage with the grooves in the block and the crankshaft main bearing cap.
Place the upper halves of the crankshaft main bearings in the cylinder block. Place the lower halves of the crankshaft main bearings in crankshaft main bearing caps.
Illustration 1 g01013519
Attach Tooling (A) and a suitable lifting device to crankshaft (6) . The weight of crankshaft (6) is approximately 129 kg (285 lb). Position the upper half of the crankshaft main bearings and crankshaft (6) in the cylinder block.
Install crankshaft thrust bearings (3) .
Install the lower half of crankshaft main bearings (5) .Note: Crankshaft main bearing caps (4) should be installed with the part number toward the right side of the engine. The numerical sequence is identified by stamped numbers 1 through 7 that are located on the bottom surface. The thrust plate is used on the number 4 crankshaft main bearing only.
Position crankshaft main bearing caps (4) with the part numbers toward the right-hand side of the cylinder block. Position crankshaft main bearing caps (4) in a numerical sequence.Note: Inspect the bolts for main bearing caps (4) . Refer to Reuse and Salvage Guidelines, SEBF8301, "Inspection and Reuse of Critical Fasteners Used in All Engines" to determine if the bolts should be replaced or reused.
Apply clean "SAE 30W" oil or molybdenum grease to the bolt threads and the washers. Install the bolts. Tighten the bolts to a torque of 150 5 N m (110 5 lb ft). Place an index mark on each bolt head. Turn the bolts for an additional 60 5 degrees (1/6 turn).
Check the end play of the crankshaft with Tooling (B) . The end play must be 0.10 to 0.50 mm (0.004 to 0.020 inch).Note: Careful handling is required for fractured connecting rods. Fractured faces for the connecting rod and connecting rod cap should not be placed on any surface. The connecting rod and the connecting rod cap should be placed on the sides in order to prevent damage. When possible, the connecting rod and the connecting rod cap should be bolted together in order to prevent damage.
Install connecting rod bearings (1) and connecting rod caps (2) .
Apply Tooling (C) to the connecting rod cap bolts. Install the connecting rod cap bolts. Tighten the connecting rod cap bolts to a torque of 130 7 N m (95 5 lb ft).
Place an index mark on each bolt head. Tighten each bolt for an additional 60 5 degrees (1/6 turn).End By:
Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Remove and Install".
Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install".
Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".