0208747 JOHNSON OWNER'S MANUAL

Table 1
Required Tools
Tool Part Number Part Description Qty
A 9S-3263 Thread Lock Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that all components of the engine oil pump are clean and free from wear or damage.
Illustration 1 g01344542
Typical example
Install inner rotor (16) and outer rotor (17). Used rotors should be installed in the original direction of rotation. Check the clearance between the outer rotor and the body of the oil pump. Check the clearance between the inner rotor and the outer rotor. Check the end play of the rotor assembly. Refer to Specifications, "Engine Oil Pump" for more information.
Lubricate the assembly of the oil pump with clean engine oil. Install front cover (15). Install bolts (14). Tighten the bolts to a torque of 26 N m (19 lb ft).
Ensure that the shaft of the oil pump is clean and dry. Position gear (13) onto the shaft. Install nut (12). Tighten the nut to a torque of 95 N m (70 lb ft). Note: Do not use a timing pin to lock the balancer in order to tighten nut (12).
Lubricate hub (9), thrust washer (11) and the bush of idler gear (10) with clean engine oil. Install hub (9) and thrust washer (11) to idler gear (10). Note: Ensure the correct orientation of the idler gear.
Install the assembly of the idler gear to balancer (1).
Ensure that the threads of bolt (8) are clean and dry. Apply Tooling (A) to the threads of the bolt. Install bolt (8). Tighten the bolt to a torque of 26 N m (19 lb ft).
Check the end play of idler gear (10). Refer to Specifications, "Engine Oil Pump".
Install the engine oil relief valve . Refer to Disassembly and Assembly, "Engine Oil Relief Valve - Remove and Install" for further information. Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
B 230-6284 Timing Pin (Crankshaft) 1
C 231-8849 Timing Pin (Balancer) 1
D 9U-7324 Indicator Bracket 1
7H-1942 Dial Indicator
3S-3268 Indicator Contact Point
7H-1940 Universal Attachment
E - Guide Bolts
(M10 by 75 mm) 1
Illustration 2 g01259627
Ensure that No. 1 piston is at the top center position and that Tooling (B) is installed to position (X) in the front housing.
Clean the mating surfaces of the cylinder block.
Illustration 3 g01252312
Install Tooling (E) to the cylinder block.
Illustration 4 g01260306
Ensure that dowels (6) and (7) are seated in the housing of balancer (1).
Illustration 5 g01252310
Install Tooling (C) to balancer (1). Ensure that Tooling (C) is engaged into shaft (5).
Attach a suitable lifting device to the balancer. The balancer weighs approximately 23 kg (51 lb).
Use the lifting device to align balancer (1) with Tooling (E). Install the balancer to the cylinder block. Ensure that dowels (6) and (7) are aligned with the holes in the cylinder block. Ensure that gear (10) and the crankshaft gear mesh. Remove the lifting device.
Illustration 6 g01259635
Install bolts (4) to balancer (1) finger tight.
Remove the Tooling (E) and install the remaining bolts (4). Tighten the bolts to a torque of 54 N m (40 lb ft).
Remove the Tooling (B) and (C).
Install suction pipe (2) and a new joint to balancer (1).
Install bolts (3). Tighten the bolts to a torque to 22 N m (16 lb ft).
Use Tooling (D) in order to check the backlash between gears (10) and (13). Refer to Illustration 4. Refer to Specifications, "Engine Oil Pump".
Use Tooling (D) in order to check the backlash between gear (10) and the crankshaft gear. Refer to Specifications, "Gear Group - Front" for further information. End By:
Install the engine oil pan. Refer to Disassembly and Assembly , "Engine Oil Pan - Remove and Install".
Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install".