0383240 JOHNSON PISTON ASSEMBLY, Less rings,.020 O.S.

TYPICAL EXAMPLE1. Remove the bolts (2) that hold exhaust elbow to support (3).2. Remove bolts (4) that hold support (3) and lifting eye (1) to cylinder block. Remove the support and lifting eye from engine.3. Disconnect water line connection from water temperature regulator housing and the manifold. Fasten a hoist to regulator housing. Remove the bolts that hold front lifting eye and support to cylinder block. Remove the water regulator housing, manifold, and lifting eye as a unit. Weight is 150 lb. (68 kg).
TYPICAL EXAMPLE4. Remove fuel line (7) from injection pump housing. governor.5. Remove the bolts (6) that hold housing to cylinder block.6. Install a 3/8"-16 NC forged eyebolt in back of housing. Fasten a hoist and remove the fuel injection pump housing, shutoff control, governor and governor drive as a unit. The weight for a D379 is 350 lb. (159 kg); for D398 is 425 lb. (193 kg); for a D399 is 500 lb. (227 kg).
Do not cause damage to the oil tube for fuel pump and governor drive when unit is removed.
Install Fuel Injection Pump Housing, Shutoff Control, Governor, And Governor Drive As A Unit
1. Put 7M7260 Liquid Gasket Material on bottom of housings and surface of contact with cylinder block. 2. Put four 3/8"-16 NC bolts (1) for a guide in the cylinder block.3. Install a 3/8"-16 NC forged eyebolt in back of housing. Fasten a hoist and put the injection pump housing, governor and governor drive in position on engine.4. Put engine oil in the bore for the oil tube. Lower the unit on the guide bolts (1). Be sure the oil tube engages the bore in the block. Install the bolts that hold unit to cylinder block. 5. Fasten a hoist to water temperature regulator housing, manifold, lifting eye and support (2). Install as a unit. Install the bolts and connect the water lines.6. Install the fuel line (3) on front of injection pump housing. 7. Install oil line (6) on the governor.8. Install the lifting eye and support (4) on back of governor drive housing.9. Install the bolts (5) that hold exhaust elbow to support.10. Make adjustment of timing; See TIMING THE FUEL INJECTION PUMP CAMSHAFT in TESTING AND ADJUSTING.end by:a) install manual shutoff controlb) install exhaust manifoldc) install fuel injection linesDisassemble Fuel Injection Pump Housing
start by:a) remove fuel injection pump housing and governor as a unitb) remove governorc) remove shutoff control (if so equipped) 1. Remove governor drive housing (1) from fuel injection pump housing. 2. Remove plate assembly (2) from fuel injection pump housing.3. Remove the cover (3) from side of housing. 4. Remove the cover (5). Remove the plug and seal (4) from housing. 5. Remove bolts and clamps that hold fuel injection pumps to the housing. Pull the pump bodies (6) straight up to remove them from housing. 6. Slide the end of each plunger out of the yoke in the lifter and pull out the plunger (7). Install the plunger in its respective pump body. Make identification on each of the fuel injection pumps by its location in the injection pump housing.
Be very careful when removing fuel injection pumps to prevent damage to plunger surfaces. The body and plunger of each are put together at the factory and cannot be used with the bodies or plungers of other pumps.
7. Remove the fuel rack (8) from housing.8. Remove the three bolts (10) and locks that hold thrust plate. Remove the thrust plate (9). 9. Use wrench (A) to hold yoke screw (11). Loosen locknuts (12). 10. Remove yoke screws (11). Put identification on each yoke screw by its location in injection pump housing. 11. Install S1605 bolts (13) (3/8"-24 NF x 3 1/4" long) and needed washers in the lifters.12. Tighten the bolts (13) enough to hold lifters away from the camshaft. 13. Remove the camshaft from housing.
Be careful when removing the camshaft. Do not cause damage to camshaft or bearings.
14. Remove the bolts (13) from the fuel pump lifters and remove lifters (14) and springs (15) from the bottom of the housing. Put identification on each of the lifters by its location in the housing. 15. Use tool group (B) to remove camshaft bearings from the housing. 16. Use tooling (C) to remove the bearings for fuel rack from the housing.Assemble Fuel Injection Pump Housing
1. Use tooling (C) to install bearings for fuel rack in housing. 2. Use tool group (B) to install camshaft bearings. Be sure the oil holes (1) in bearings are in alignment with oil hole in housing.
Be sure the tool group (B) is in center position on bearing while installing bearings, so no damage will be caused to them.
3. Put clean engine oil on lifters (2). Install the lifters (2) in their respective position in housing.4. Push the lifters in the housing against their springs. 5. Install S1605 bolts (3) (3/8"-24 NF x 3 1/4" long) and needed washers (4) in the lifters.6. Tighten the bolts (3) enough to hold lifters up to install camshaft. 7. Put clean engine oil on the camshaft bearings.8. Install the camshaft in the housing. If the engine has a counterclockwise rotation, the camshaft is installed with the arrow and the F-mark (5) at the front of pump housing as shown. For clockwise rotation of engine, the camshaft is installed with the F-mark and arrow at the rear of pump housing.9. Remove the bolts and washers that were used to hold lifters up. 10. Install the thrust plate (6), locks and bolts that hold camshaft in housing. 11. Install yoke screws (7) and locknuts in their respective position in housing. Use wrench (A) to hold yoke screw while locknut is tightened.12. Make adjustment to lifters. See FUEL PUMP TIMING DIMENSION SETTING (OFF ENGINE) in TESTING AND ADJUSTING. 13. Put clean