0382706 JOHNSON GAS CAP ASSEMBLY

2. Turn the crankshaft until two pistons are at bottom center.3. Remove nuts (1) and the bearing caps. Push the rods and pistons up until the rings are out of the cylinder liners. 4. Remove pistons (2) and connecting rods from the cylinder liners.5. Do Steps 1 through 4 for the remainder of the pistons and connecting rods.Install Pistons & Connecting Rod Assemblies
1. Put clean engine oil on piston rings, connecting rod bearings and cylinder liners. 2. Use Tool (A), and install piston (2) and the connecting rod in the cylinder liner. Be sure the number on the tab groove side of the connecting rod is on the opposite side from the camshaft.3. Install the bearing cap on the connecting rod with the number on the side of the bearing cap on the same side and same number as on the connecting rod.4. Put 4C-5593 Anti-Seize Compound on the threads of the bolts and the seating faces of the connecting rod caps. Install the nuts, and tighten them to a torque of 90 8 N m (65 6 lb ft). Put a mark on the nuts and cap, and tighten the nuts an extra 90 5 degrees.5. Do Steps 1 through 4 for the remainder of the pistons and connecting rods.End By:a. install oil pumpb. install cylinder head assembly.Disassemble & Assemble Pistons & Connecting Rod Assemblies
Start By:a. remove pistons and connecting rod assemblies 1. Remove bearings (3) from the connecting rod and connecting rod cap.2. Remove retainer ring (1) and Tool (A).3. Remove pin (2) and connecting rod (4) from the piston. 4. Remove piston rings (5) from the piston with Tool (B). Clean the piston ring grooves on the pistons with an acceptable ring groove cleaning tool. See, Use Of Piston Pin Bearing Removal & Installation Tools, Special Instructions, SMHS7295.5. Heat connecting rod (4) in an oven to a temperature of 177 °C to 260 °C (350 °F to 500 °F). Never use a direct flame to heat a connecting rod. 6. Put connecting rod (4) in position on the base plate of Tooling (C). Put a new rod pin bearing (6) on the adapter part of Tooling (C). The old bearing is pushed out by Tooling (C) as the new bearing is installed.7. Use Tooling (C) to push the new bearing into the connecting rod until the push adapter of Tooling (C) makes full contact with the connecting rod surface.8. Use a pin boring machine to make the rod pin bearing the correct size. The bore in the new rod pin bearing must be 50.830 0.008 mm (2.0012 .0003 in).9. Check the clearance between the ends of the piston rings. See the topic "Pistons and Rings", in the Specifications manual.10. Install the oil ring spring in the oil ring groove of the piston. The oil ring is to be installed over the spring with the oil ring end gap 180 degrees from the oil ring spring joint.11. Install the oil ring on the piston with Tool (B).12. Install the second (intermediate) piston ring with the side that has the identification "UP-2" toward the top of the piston. Use Tool (B) to install the ring.13. Install the first (top) piston ring with the side that has the identification "UP-1" toward the top of the piston. Use Tool (B) to install the ring. After the installation of all three piston rings, put the piston rings in position so the end gaps are 120 degrees apart.14. Put the piston in position on connecting rod (4). Put clean engine oil on pin (2), and install the pin. Install retainer rings (1) with Tool (A). Make sure the retainer rings are in the grooves of the piston.15. Install bearings (3) in the connecting rod and connecting rod cap. Be sure the tabs in back of the bearings are in the tab slots of the connecting rod and connecting rod cap.End By:a. install pistons and connecting rod assemblies