0584305 JOHNSON LEAD ASSY., Ground

5-1-1 Removal and Installation
1 Cooling fan2 Spacer3 Water pump pulley4 V-belt<D3: Option> 1 Cooling fan2 Auto cool fan coupling3 Water pump pulley4 V-belt5-1-2 Inspection of Auto Cool Fan Coupling <Option: D3>
The auto cool fan coupling is a non-maintainable assembly requiring no silicone oil maintenance and it must be replaced as an assembly if defective. (1) While the engine is cold, move the entire fan coupling unit in the axial direction. If there is an excessive play, the bearing is defective requiring replacement. (2) Carefully turn the fan by hand. If the fan turns more than the limit even when you let it go, replace the auto cool fan coupling. While the fan is turning, ensure that the bearing rotates smoothly. (3) If there is mud, dust, or dirt on the bimetal, clean with wire brushes. Do not apply excessive force to the bimetal during cleaning.5-2 Water Pump
5-2-1 Removal and Installation
1 Bypass hose2 Water pump assembly5-2-2 Disassembly and Inspection
(1) D3 <Disassembly sequence> For disassembly of parts with an encircled number, see following items. (a) Using gear puller, remove the flange. (b) After removing the snap ring, withdraw the water pump shaft together with the ball bearing by using a press and remove the impeller. Heating the water pump case to approximately 80°C helps make the job easier. (c) Check the unit seals installed in the impeller and water pump case for damage and wear. If defects are evident, or when water leaks during operation, replace the unit seals with new ones. Whenever the unit seal is removed, it must be replaced with a new one. When the unit seals alone are to be replaced, tap two holes in the impeller to M8 and, using Water Pump Impeller Puller (special tool), remove the impeller. (d) Using a gear puller or press, remove the ball bearings. Do not remove the snap ring from the water pump shaft. (e) When the impeller and flange are removed from the water pump shaft, it may result in insufficient interference. If they are reassembled three times or more, or if the interference is below the specification even reassembly is two times or less, they must be replaced with new ones.(2) DR <Disassembly sequence> For disassembly of parts with an encircled number, see following items. (a) Remove the flange with Puller (special tool). (b) Remove the snap ring and, using a press, remove the water pump shaft with the ball bearing to remove the impeller. Heating the water pump case to about 80°C makes the job easier. (c) Check the unit seal fitted into the impeller and water pump case for damage and wear. If defects are evident, or if water leaks during operation, replace the unit seal. Whenever the unit seal is removed, it must be replaced with a new one. When the unit seals alone are to be replaced, tap two holes in the impeller to M8 and, using Water Pump Impeller Puller (special tool), remove the impeller. (d) Using a gear puller or press, remove the ball bearings. Do not remove the snap ring from the water pump shaft. (e) When the impeller and flange are removed from the water pump shaft, it may result in insufficient interference. If they are reassembled three times or more, or if the interference is below the specification even reasembly is two times or less, they must be replaced with new ones.5-2-3 Reassembly
(1) D3 1. After reassembly, install the water pump onto the timing gear case and make sure that the impeller is not in contact with the timing gear case.2. Reassembly of the flange and impeller into the water pump shaft is allowed up to two times.(2) DR 1. After reassembly, turn the water pump shaft by hand and make sure that the impeller is not in contact with the case and cover.2. Reassembly of the flange and impeller into the water pump shaft is allowed up to two times.5-3 Thermostat
5-3-1 Removal and Installation
1 Thermostat cover2 Thermostat3 Thermostat case4 Bypass pipe 1 Thermostat cover2 Thermostat3 Water outlet pipe5-3-2 Inspection
Agitate water in the container with the stirrer to obtain uniform temperature. For the inspection, use the following procedures.(1) Slowly heat water to the thermostat valve opening temperature. Keep this condition for about five minutes and make sure that the valve is open.(2) Raise the water temperature up to 95°C. Keep the condition for five minutes and measure the lift of pellet.(3) Lower temperature down to 65°C or below and ensure that the valve is fully closed. If the thermostat is found defective in any of the above items, replace it with a new one. Support the thermostat so that the heat will not directly transfer to it.5-4 Radiator
5-4-1 Inspection
(1) Using a copper wire or similar device, remove dirt, mud, and bugs from the front of radiator core with care to prevent damage to tubings. (2) Connect a hose to one of the radiator ports, cap the other port, and immerse the radiator into water. Using a radiator cap tester, force the compressed air under the specified inspection pressure from the hose end to check for leaks. If there is a leak, resolder the point of leakage or replace the radiator. (3) Inspection of Radiator Cap Check the spring tension and sealing condition of the pressure valve and vent valve. If defective, replace.Check the pressure valve opening pressure, using a radiator cap tester.5-5 Inspection and Adjustment of V-belt Tension
(1) Adjust the belt tension to obtain the specified belt deflection when the center of each belt is pressed with a force of approximately 98 N (10 kgf). 1. A slack belt can be a cause of overheating and undercharge.2. An excessively tight belt may result in damaged bearings and bel