0211295 JOHNSON OWNERS MANUAL

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 6V-4020 Piston Ring Expander 1
D 5P-8639 Hydraulic Press 1
8F-0024 Hose Assembly 1
1P-2375 Quick Connect Coupler 1
1P-2376 Quick Connect Coupler 1
1U-5230 Hand Hydraulic Pump 1
E 5P-8649 Adapter 1
F 6V-3043 Spacer 1
G 6V-3042 Adapter 1
H 1U-7616 Piston Ring Compressor Gp 1
J 334-0519 Grease 1
K 471-6593(2) Installer Assembly 1
(1) The 9S-9082 Engine Turning Tool is alternative tooling.
(2) For applications with cuffed liners.Start By:
Remove the cylinder head.
Remove the piston cooling jets.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: The front end of the engine is the end that is opposite of the flywheel. The number one cylinder is the right front cylinder and the number two cylinder is the front left cylinder.
Remove the cover from the front right side of the flywheel housing. Use Tooling (A) to rotate the flywheel until all four bolts in the connecting rod cap can be removed.
Mark the cylinder number on each connecting rod and on the corresponding connecting rod cap.
Illustration 1 g00913801
Illustration 2 g01051820
Remove bolts (1) and connecting rod cap (2) from connecting rod (5).
Remove the piston and connecting rod assembly.
Use Tooling (B) to remove the retaining rings that hold piston pin (4). Remove piston pin (4). Remove piston (3) from connecting rod (5).
Remove the bearings from connecting rod (5) and from connecting rod cap (2).
Illustration 3 g06155340
Use Tooling (C) to remove piston rings (6) from piston (3).
Clean the piston ring grooves with an acceptable ring groove tool. Refer to Guideline For Reusable Parts, SEBF8059, "Procedure To Clean And Inspect 3500 Series Engine Pistons" for the correct procedure for cleaning the pistons.
Illustration 4 g01208346
Raise the temperature of connecting rod (5). Place Tooling (F) in the base plate of Tooling (D). Place connecting rod (5) on the base plate.Note: Do not use a direct flame to heat connecting rod (5).
Place the piston pin bearing in the center of the port assembly on Tooling (D). Install pin (9) in the center of the bore for the piston pin.
Install Tooling (E). Align the hole in Tooling (E) with the hole that is in the base plate of Tooling (D).
Install bar clamp (11) and clamp pin (10).Note: The old bearing is pushed out while the new bearing is installed.
Position Tooling (G) with the tapered side facing downward. The piston pin bearing joint must be aligned with the hole in Tooling (E) and the hole in the base plate of Tooling (D).
Place pusher (7) on Tooling (G).
Use Tooling (D) to push new piston pin bearing (8) into connecting rod (5) until Tooling (G) makes contact with connecting rod (5).
Remove connecting rod (5) and the old piston pin bearing from Tooling (D).
After the piston pin bearing is installed, measure the diameter of the bearing bore. The correct diameter is 70 0.01 mm (2.8 0.000 inch).Installation Procedure
Illustration 5 g06155340
Use Tooling (C) to install piston rings (6) onto the piston.
For the oil control ring, ensure that the ends of the spring are 180 degrees from the ring gap. The white portion of the spring must be visible at the ring gap.
Install the intermediate ring with the side marked "UP-2" toward the top of the piston.
Install the top ring with the side marked "UP-1" toward the top of the piston.
After the rings are installed, rotate the rings so that the gaps are spread apart by 120 degrees. Orient the oil control ring gap toward the bore for the piston pin.