5037546 JOHNSON GEARCASE Assy - WHITE

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1U-9895 Crossblock 1
3H-0465 Push-Puller Plate 2
8F-6123 Bolt 2
0S-1575 Bolt 4
- Washer (3/4 inch Copper) 4
B 8T-0455 Liner Projection Tool Group 1
C 2P-8260 Cylinder Liner Installer 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Install the spacer plate gasket and the spacer plate. Refer to Disassembly and Assembly, "Spacer Plate - Remove and Install". Note: Ensure that all surfaces are clean and dry when the spacer plate gasket is installed.
Clean the cylinder liner and the cylinder bore in the cylinder block.
Position the cylinder liner in the cylinder bore without the seals or the filler band.
Illustration 1 g00578873
Typical example
Use the following steps to check the cylinder liner projection:
Install four bolts (4) and the washers from Tooling (A). Tighten the bolts evenly in four steps. Step 1 ... 14 N m (10 lb ft)Step 2 ... 35 N m (25 lb ft)Step 3 ... 70 N m (50 lb ft)Step 4 ... 95 N m (70 lb ft)
Install crossbar (2), plates (3), and bolts (1) from Tooling (A). Ensure that crossbar (2) is in position at the center of the cylinder liner. Also ensure that the surface of the cylinder liner is clean. Tighten bolts (1) evenly in four steps. Step 1 ... 7 N m (5 lb ft)Step 2 ... 20 N m (15 lb ft)Step 3 ... 35 N m (25 lb ft)Step 4 ... 70 N m (50 lb ft)
Check the distance from the bottom of crossblock (2) to the top of the spacer plate. The distance at both ends of the crossbar must be equal.
Check the liner projection with Tooling (B) at four locations on the cylinder liner. The cylinder liner projection must be 0.129 0.070 mm (0.0051 0.0028 inch). A distance of 0.05 mm (0.002 inch) must be the maximum difference between the measurements. Note: If the cylinder liner is turned in the cylinder block, there will be a difference in the liner projection.
Illustration 2 g00578874
If the liner projection is not 0.129 0.070 mm (0.0051 0.0028 inch), check the thickness of the following items: (5) Spacer plate ... 12.313 0.025 mm (0.4848 0.0010 inch) (6) Spacer plate gasket ... 0.208 0.025 mm (0.0082 0.0010 inch) (7) Cylinder liner flange ... 12.65 0.02 mm (0.498 0.001 inch)
Place an alignment mark on the cylinder liner and the cylinder block in order to install the cylinder liner in the same position.
Remove Tooling (A), Tooling (B), and the spacer plate. Also remove the cylinder liner.
Illustration 3 g00578875
Typical example
Apply liquid soap to seals (5), the grooves of the cylinder liner, and the cylinder block.
Install seals (5) on the cylinder liner.
Dip the filler band (6) in clean engine oil. Immediately install filler band (6) in the groove that is under the cylinder liner flange.
Illustration 4 g00578876
Typical example
Install the cylinder liner immediately after filler band (6) is installed on the cylinder liner. Ensure that the marks that are on the cylinder liner and the cylinder block are aligned.
Use Tooling (C) to press the cylinder liner into the cylinder block. End By:
Install the pistons and the connecting rod assemblies. Refer to Disassembly and Assembly, "Piston and Connecting Rods - Install".