0438529 JOHNSON MOTOR & O-RING ASSY.

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 9U-6198 Crankshaft Turning Tool 1
A(2) 9U-7336 Housing 1
5P-7305 Engine Turning Tool 1
B 367-8608 Engine Timing Pin 1
C 298-5564 T40 Torx Socket 1
D 227-4389 E10 Torx Socket 1
E 370-4657 Rocker Arm Spacer 6
F 322-4113 Retainers 24
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g03454236
The correct location of valve bridges on valve stems is shown.
Engines that have valve bridge clips (9) originally installed on valve bridges (5). Remove the valve bridge clips from the valve bridges.
Clean valve bridges (5). Inspect the valve bridges for wear and damage. Replace any valve bridges that are worn or damaged.
Install Tooling (F) onto valve bridges (5).
Lubricate valve bridges (5) with clean engine oil.
Failure to ensure that ALL valve bridges are correctly seated onto the valve stems will cause interference between the pistons and the valves, resulting in damage to the engine.
Install valve bridges (5) to the valve stems. Ensure that valve bridge clips (9) are correctly located.Note: Install used valve bridges in the original location and in the original orientation. Ensure that the valve bridges are correctly seated on the valves. New valve bridges may be installed in either orientation.
Illustration 2 g03454237
Clean the pushrods. Inspect the pushrods for wear and damage. Replace any pushrods that are worn or damaged.
Apply clean engine lubricating oil to both ends of pushrods (8). Install the pushrods to the engine with the cup upward. Ensure that when the pushrods are installed into the hydraulic lift there should be a noticeable snap when the pushrods are correctly installed.Note: Ensure that the pushrods are installed in the original location.
Illustration 3 g02085993
If necessary, use Tooling (A) to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Position the Valve Mechanism Before Maintenance Procedures" for the correct procedure. Install Tooling (B) through Hole (W) to lock the crankshaft.Note: Do not use excessive force to install Tooling (B). Do not use Tooling (B) to hold the crankshaft during repairs.
Remove Tooling (B).
Failure to ensure that the crankshaft is positioned at 60 degrees after top dead center will result in interference between the pistons and the valves. Failure to ensure that the crankshaft is positioned at 60 degrees after top dead center will result in damage to the engine.
Use Tooling (A) to rotate the crankshaft in a clockwise direction and position the crankshaft at 60 degrees after top dead center.
Illustration 4 g03454356
Illustration 5 g02307257
Ensure that the rocker shaft assembly is clean and free from wear and damage.
Position the rocker shaft assembly with Spotfaces (Y) for Torx screws (6) is in the up ward position.
Install Tooling (E) to rocker shaft assembly.
Install Torx screws (6) to the rocker shaft.Note: Ensure that correct Torx screw (6) is installed to Position (X).