0394021 JOHNSON PRIMER PUMP ASSY.

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     9S-9082     Engine Turning Tool     1    
B (1)     5P-3526     Piston Ring Compressor     1    
B (2)     200-3914     Piston Ring Compressor     1    
C     8T-3052     Degree Wheel     1    
( 1 ) For use with the C15 engine.
( 2 ) For use with the C18 engine.
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.
Apply clean engine oil to the cylinder liner bore, to the piston rings, and to the outer surface of the piston.Note: The piston and connecting rod are matched to a specific cylinder. Ensure that the connecting rod and pistons are installed in the correct cylinder.
Use Tooling (A) to rotate the crankshaft until the connecting rod journal is at the bottom center.
Illustration 1 g01048560
Note: Be careful not to damage the cylinder liner, the crankshaft journal during installation of the piston and the connecting rod.
Use Tooling (B) to install piston (3) and the connecting rod in the cylinder liner.Note: Install the connecting rod so that the bearing tab is located on the side of the piston cooling jet.
Install the upper connecting rod bearing in the connecting rod.Note: Ensure that the connecting rod bearing is installed so that the bearing tab fits into the notch in the connecting rod.
Lubricate the connecting rod bearing with clean engine oil and pull the connecting rod onto the crankshaft journal.
Install the lower connecting rod bearing in the connecting rod bearing cap.Note: Ensure that the connecting rod bearing is installed so that the bearing tab fits into the notch in the connecting rod.
Illustration 2 g01016640
Position connecting rod bearing cap (2) on the connecting rod.Note: Ensure that the number on the side of the connecting rod bearing cap is on the same side as the number on the connecting rod. The bearing tabs of the connecting rod bearing cap and the connecting rod are located on the side of the piston cooling jet.
Lubricate the threads of bolts (1) with clean engine oil and install bolts (1) .
Tighten bolts (1), as follows:
Tighten Bolt (A) and Bolt (C) to a torque of 70 4 N m (52 3 lb ft).
Tighten Bolt (B) and Bolt (D) to a torque of 70 4 N m (52 3 lb ft).
Turn Bolt (B) and Bolt (D) for an additional 60 5 degrees (1/6 turn).Note: If Tooling (C) is not used, place an index mark on each bolt.
Tighten Bolt (A) and Bolt (C) to a torque of 70 4 N m (52 3 lb ft).
Turn Bolt (A) and Bolt (C) for an additional 60 5 degrees (1/6 turn).Note: If Tooling (C) is not used, place an index mark on each bolt.
Rotate the crankshaft in order to ensure that the crankshaft turns freely.End By:
Install the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets - Remove and Install".
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".