0114805 JOHNSON GEARCASE ASSY., Complete

2. Remove the bolts that hold the rear support assembly to the frame. Install two 1/2"-13 NC forged eyebolts in the rear support assembly as shown. Fasten a hoist and remove rear support assembly (1) and the door assemblies as a unit. The weight is 400 lb. (181.4 kg).3. Disconnect the two oil lines from the hydraulic oil cooler. Put plugs in the lines to prevent loss of hydraulic oil.4. Disconnect the fuel supply line from the fuel tank to prevent loss of fuel. Remove the fuel return and fuel supply lines, that go between the fuel lines connected to the fuel tank and the engine. 5. Disconnect muffler support (2) from the flywheel housing. Let support hang along the frame. 6. Disconnect the two wiring connectors (6). Disconnect engine oil pressure line (4).7. Disconnect cables (5) and (3) from the starter. Disconnect wire from hydraulic oil filter.8. Disconnect the governor control linkage from the lever on the governor. Remove the two bolts that hold the bracket for the control linkage to the pump housing. Let the linkage and bracket hang along the engine.9. Disconnect the fuel pressure line from the fuel injection pump housing.10. Disconnect the two heater hoses (if so equipped) from the engine.11. Put a support in position under the axial piston pumps.12. Fasten a hoist and chain to the rear lifting eye. Connect ratchet pullers (A) to the hoist. Connect one of the pullers to the front lifting eye. Connect the other puller to the spacer between the timing gear plate and muffler support.13. Remove bolts that hold the engine front support to the frame. Remove bolts that hold flywheel housing to pump drive housing.14. Move the engine away from the pump drive. Lift the engine until the oil pan is above the frame. Lift the front of the engine with tools (A) until the front support is above the top of the counterweight. Remove the engine and radiator from the chassis. The weight is 2000 lb. (907.2 kg).Install Engine And Radiator
1. Fasten a hoist and a chain to the rear lifting eye. Connect ratchet pullers (A) to the hoist. Connect one of the pullers to the front lifting eye. Connect the other puller to the spacer between the timing gear plate and muffler support. 2. Put the engine and radiator in position in the chassis. Move the engine into position on the pump drive housing using tools (A) to put the flywheel housing in alignment with the pump drive housing. Install bolts (1). 3. Install the spacers and bolts (2). Tighten the bolts to a torque of 90 15 lb.ft. (12.4 2.1 mkg).4. Remove support under axial piston pumps.5. Install fuel lines (4) and (5). Connect the fuel supply line to the fuel tank. 6. Install the bolts that hold muffler support (3) to the flywheel housing.7. Connect the fuel pressure line to the fuel injection pump housing.8. Install the bolts that hold the bracket for the governor linkage to the pump housing. Connect the governor linkage to the governor.9. Connect the cables to the starter. Connect the wire to the hydraulic oil filter.10. Connect the engine oil pressure line. Connect the two wiring connectors.11. Connect the two heater hoses (if so equipped) to the engine.12. Connect the two hydraulic oil lines to the hydraulic oil cooler.13. Install two 1/2"-13 NC forged eyebolts in the rear support assembly. Fasten a hoist and put the rear support assembly in position on the frame. Install the bolts that hold the rear support assembly to the frame.14. Connect the battery cables to the battery. Fill the engine with oil to the correct level. Fill the cooling system with coolant to the correct level.end by: a) install muffler