0210984 JOHNSON OWNERS MANUAL, Ev.

Table 1
Required Tools
Tool Part Number Part Description Qty
A 5R-7425 Barring Gp (1) 1
B 1P-1861 Retaining Ring Pliers 1
C 271-0498 Expander Ring 1
D 1U-7616 Piston Ring Compressor Gp 1
E 334-0519 Grease -
(1) The 9S-9082 Engine Turning Tool is alternative tooling.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Install the connecting rod bearings dry when clearance checks are performed. Refer to Disassembly and Assembly, "Bearing Clearance - Check". Apply clean engine oil on the connecting rod bearings for final assembly.
Illustration 1 g03854763Note: Ring grooves are to be 100% lubricated with clean engine oil prior to the installation of the rings.
Use Tooling (C) to install the piston rings onto the piston.
The oil ring spring ends to be assembled 180° from ring end gap.
Install intermediate piston ring with side marked "UP-2" toward top of the piston.
Install the top piston ring with side marked "UP-1" toward top of the piston.
After the rings have been installed, rotate the rings so the end gaps are 120° apart. Oil ring end gap must be in pin bore plane. Note: After assembly the mating surfaces from ring to liner must be 100% lubricated with clean engine oil.
Illustration 2 g03422403
Use clean engine oil to coat the bore of piston (3), piston pin (4), and the piston pin bearing in the connecting rod (5). Position connecting rod (5) inside piston (3). Insert piston pin (4) through piston (3) and the bearing.
Use Tooling (B) to install the retaining rings (6). Orient the retaining ring (6) gaps toward the top of piston (3). Note: Pin mating surfaces: from pin to pin-bore and pin to rod eye bearing must be 100% lubricated with clean engine oil prior to assembly.
Illustration 3 g02142782
Use Tooling (A) to rotate the crankshaft until the connecting rod journal is at the bottom center.
Use Tooling (D) to install the piston assembly in the cylinder liner. Note: Be careful not to damage the cylinder liner or the crankshaft journal during the installation of the piston assembly and the connecting rod.
Illustration 4 g03854941
Illustration 5 g02143105
Bolt tightening sequence for the connecting rod caps
Install the upper half of the connecting rod bearing on the connecting rod. Ensure that the connecting rod bearing is installed so that the bearing tab fits into the notch in the connecting rod. Coat the connecting rod bearing with clean engine oil. Position the connecting rod onto a journal of the crankshaft.
Install the lower half of the connecting rod bearing on connecting rod cap (2). Ensure that the connecting rod bearing is installed so that the bearing tab fits into the notch in the connecting rod cap. Coat the connecting rod bearing with clean engine oil. Note: The number that is on the side of the connecting rod caps must be installed next to the corresponding number that is on the side of the connecting rod. Install the chamfered side of the connecting rod cap next to the thrust surface of the crankshaft.Note: Reman connecting rods are not numbered for the cylinder position.
Apply Tooling (E) to the threads, the shank, and the seat of bolts (1).
Place connecting rod cap (2) into position. Install bolts (1). Use the following procedure to tighten the bolts:
Tighten Bolt (A) and Bolt (B) to a torque of 90 5 N m (65 4 lb ft).
Tighten Bolt (C) and Bolt (D) to a torque of 90 5 N m (65 4 lb ft).
Tighten Bolt (C) and Bolt (D) again to a torque of 90 5 N m (65 4 lb ft).
Place an index mark on the bolts and the connecting rod cap. Tighten each bolt for an additional 90 5 degrees (1/4 turn).
Rotate the crankshaft in order to ensure that the crankshaft turns freely.