0434764 JOHNSON GEARCASE ASSY., Complete

1. Disconnect connector (1). 2. Attach Tool (A) and fasten a hoist.3. Remove four bolts (3) and stack (2). The weight of the stack and hardware is 45 kg (99 lb). 4. Remove hose clamp (6).5. Remove five bolts (5) and support (4).6. Repeat Steps 4 and 5 for the other side of the engine. 7. Remove six bolts (7) that connect oil pan (8) to flywheel housing (9). Loosen the rest of the bolts that hold the oil pan in position. 8. Attach Tool (A) to the flywheel housing and a hoist. 9. Lift the end of the engine enough so a 1/2 ( in) Hardened Washer (10) can be installed on each side of the engine between the oil pan and the cylinder block.10. Install blocks under the oil pan to support the engine when the flywheel housing is removed. Lower the engine onto the blocks. 11. Remove twenty one bolts (11) and flywheel housing (9). The weight of the flywheel housing is approximately 91 kg (201 lb).Install Flywheel Housing
1. Install two 1/2 in-13 NC × 101 mm (4 in) Long Guide Bolts in the cylinder block. Make sure gasket (12) is in position. The cylinder block, both sides of gasket (12) and the surface of the flywheel housing that makes contact with the gasket must not have any oil, fuel, water or gasket adhesive on them when the flywheel housing is installed on the engine.2. Install Tool (A) on the flywheel housing. Install flywheel housing (9) on the engine. The weight of the flywheel housing is approximately 91 kg (201 lb). Leave Tool (A) attached.
Torque Sequence Put 9S-3263 Thread Lock on bolts (17) through (20) before installation.3. Install the bolts that hold the flywheel housing in place.4. Use the following procedure to tighten the bolts: a. Tighten bolts 1 through 20 in number sequence to a torque of 40 10 N m (30 7 lb ft).b. Tighten the 3/8" bolts in number sequence to a torque of 55 10 N m (41 7 lb ft). Tighten the 1/2" bolts in number sequence to a torque of 135 20 N m (100 15 lb ft). If a new gasket is installed, cut the ends of the gasket so it is even with the bottom of the cylinder block.5. Use Tool (A) and a hoist to lift the flywheel housing and engine enough so that the washers between the oil pan and the cylinder block can be removed. 6. Tighten the bolts that hold the oil pan to the cylinder block. Install six bolts (7) that hold oil pan (8) to flywheel housing (9). 7. Install support (4) with five bolts (5). Install clamp (6) to a torque of 7.0 1.5 N m (5 1 lb ft).8. Repeat Step (7) for the other side of the engine. 9. Use Tool (A) to lift stack (2) in place. Install the stack to the engine with four bolts (3). 10. Connect connector (1).End By:a. install crankshaft rear seal and wear sleeveb. install all turbochargers