0314915 JOHNSON LEAF

1. Disconnect tube (1) from carburetor and remove bolt (2) and clip from carburetor base.2. Loosen clamp (3) to remove pipe from coupling. 3. Remove four bolts (4) that fasten gas pressure regulator to cylinder block. Remove the gas pressure regulator and tube and pipe assembly.4. Remove bolts (5) that hold inspection cover to block. Remove cover (6). 5. Turn the crankshaft (in the direction of normal rotation) until the rod caps (8) can be removed through the openings. Remove bolts (7) and rod caps (8). 6. Remove the carbon ridge (9) from the top of the cylinder liner.7. Push the connecting rod and piston up until the rings are out of the cylinder liner. 8. Remove the piston and connecting rod from the cylinder liner.Install Pistons
1. Put clean SAE 30 engine oil on the piston, rings, connecting rod bearings and walls of cylinder liner. Install upper bearing in connecting rod. 2. Install piston (1) in tool (A). Put the piston and tool (A) in position on the cylinder liner as shown.3. Install the piston in the liner slowly on to the journal of crankshaft. Be sure the "V" mark on piston is in alignment with the "V" mark (2) on the block.
Be careful not to cause damage to connecting rod bearing or journal on crankshaft when piston is installed.
4. Install the lower bearing (5) in the cap (3) for the connecting rod (4). Be sure the tab on back of bearing fits in groove for tab in cap. Install the cap.5. Put 5P3931 Anti-Seize Compound on threads of rod bolts. Install rod bolts. Tighten the rod bolts to a first torque of 40 4 lb.ft. (55 5 N m). Put a mark on bolt heads and bearing caps. Tighten the bolts again 120° from the mark.6. Put inspection covers in position on engine. Install the bolts that hold covers to cylinder block.7. Check the inspection cover gasket for damage and make a replacement of gasket if necessary. 8. Put cover (6) in position and install bolts. 9. Put gas pressure regulator (9) in position and install four bolts. Connect pipe (10) to coupling with clamp and tube assembly (7) to carburetor. Install clip (8) and bolt on carburetor base.end by:a) install oil pressure relief valveb) install engine oil pumpc) install water pumpd) install engine oil coolere) install cylinder headsDisassemble Pistons
start by:a) remove pistons 1. Use tool (A) to remove piston rings (1) from piston. 2. Remove retainers (6) and pin (4) from the piston (2). Remove connecting rod (3) from the piston.
Do not use a broken ring or carbon scraper to clean carbon. They will cut the ring grooves or cause damage to piston.
3. Remove the carbon from ring grooves on piston. 4. Use tooling (B) to remove and install the piston pin bearing (5). See SPECIAL INSTRUCTIONS, Form No. SMHS7295, for more information.Assemble Pistons
1. To find the correct piston to rod location, make an alignment of the "V" on the piston to the "V" on the block. Install the rod (3) on the piston (2) with the part number on the radius side (R) of the rod toward the radius of the crankshaft journal. 2. Install pin (1) and two retainers (6). Each retainer must fit in a groove on each end of pin (1). 3. Use ring expander (A) to install the piston rings.4. Install spring for oil control ring (bottom ring) in the bottom ring groove of piston. Install oil control ring (4) so the end gap of oil control ring (4) is 180° from the ends of spring.5. Install center ring (5) in center groove of piston so the mark "UP" on ring is toward top of piston. Install top ring in top groove of piston so the mark "UP" on ring is toward top of piston.6. Turn the piston rings in the grooves so the ring gaps are 120° apart.end by:a) install piston