0209365 JOHNSON OWNER'S MANUAL

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 1U-6684 Piston Ring Compressor 1
C 8T-3052 Degree Wheel 1
(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.
Discard all used connecting rod bolts.
If the connecting rod caps were temporarily installed, remove the connecting rod caps. If necessary, thoroughly clean all of the components.
Apply clean engine oil to the cylinder bore, to the piston rings, to the outer surface of the piston and to the connecting rod bearings. Note: Install the connecting rod bearings dry when clearance checks are performed. Refer to Disassembly and Assembly, "Bearing Clearance - Check". Apply clean engine oil to the connecting rod bearings during final assembly.
Use Tooling (A) to rotate the crankshaft until the crankshaft pin is at the bottom center position. Lubricate the crankshaft pin with clean engine oil.
Illustration 1 g01253096
Typical example
Ensure that the gaps for the piston rings are at 120 degrees away from each other. Install Tooling (B) onto piston (3). Note: Ensure that Tooling (B) is installed correctly and that the piston can easily slide from the tool. Ensure that the piston and the connecting rod assembly are installed in the correct cylinder. The arrow on the top of the piston must be toward the front of the engine.
Carefully push the piston and the connecting rod assembly into the cylinder bore and onto the crankshaft pin. Note: Do not damage the finished surface of the crankshaft pin.
Illustration 2 g01344572
Typical example
Install connecting rod cap (2) onto the connecting rod. Note: Ensure that etched number (X) on the connecting rod cap matches the etched number on the connecting rod. Ensure the correct orientation of connecting rod cap (2).
Install new bolts (1) to the connecting rod. Tighten the bolts evenly to a torque of 18 N m (13 lb ft).
Tighten the bolts evenly to a torque of 70 N m (52 lb ft).
Use Tooling (B) to turn the bolts through an additional 120 degrees.
Ensure that the installed connecting rod assembly has tactile side play. Carefully rotate the crankshaft in order to ensure that there is no binding.
Repeat Steps 2 through 10 in order to install the remaining pistons and connecting rods. Note: If all pistons and connecting rods require replacement the procedure can be carried out on two cylinders at the same time. The procedure can be carried out on the following pairs of cylinders. 1 with 4 and 2 with 3. Ensure that both pairs of the pistons and connecting rods are installed before changing from one pair of cylinders to another pair of cylinders..
Check the height of the pistons above the top face of the cylinder block. Refer to Systems Operation, Testing and Adjusting, "Piston Height - Inspect" for the correct procedure. End By:
Install the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets - Remove and Install".
If the engine is equipped with a balancer, install the balancer. Refer to Disassembly and Assembly, "Balancer - Install". If the engine is not equipped with a balancer, install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install".
Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".