0389561 JOHNSON RMT CONT ASSY. 115, 140 HP

Illustration 1 g00365332
Instructions for 1U-6431 Piston Ring Groove Gauge Piston Rings C30
The top two rings are the KEYSTONE rings, which are tapered. A special 224-9760 Piston Ring Groove Gauge is available to check the top two ring grooves in the piston. Refer to Guideline For Reusable Parts, "Pistons And Cylinder Liners".Connecting Rods And Pistons
3412E
Use the 7M-3978 Ring Expander to remove piston rings or install piston rings.Use the 5P-3526 Piston Ring Compressor to install pistons into the cylinder block.Tighten the connecting rod nuts in the step sequence that follows:
Apply 4C-5593 Anti-Seize Compound to the threads of the bolts and the contact surfaces of the bolt head.
Tighten all nuts to the following torque.Torque for nuts ... 82 8 N m (60 6 lb ft)
Put an alignment mark on each cap and bolt.
Tighten the nuts from the mark to the following value.Angle from the mark. ... 120 5 degrees C30
Use the 7B-7974 Piston Ring Expander to remove piston rings or install piston rings.Use the 200-3914 Piston Ring Compressor to install pistons into the cylinder block.
Illustration 2 g00875778
Connecting rod boltsUse the following procedure to tighten the connecting rod bolts:
Put engine oil on the bolt threads and the contact surfaces before assembly.
Tighten the bolts in the following order.Torque for bolts (1) and (3) ... 70 4 N m (52 3 lb ft)Torque for bolts (2) and (4) ... 70 4 N m (52 3 lb ft)Additionally tighten each bolt. (2) and (4) ... 60 5 degreesTorque for bolts (1) and (3) ... 70 4 N m (52 3 lb ft)Additionally tighten each bolt. (1) and (3) ... 60 5 degreesConnecting Rod Bearings
The connecting rod bearings fit tightly in the bore in the rod. If the bearing joints are fretted, check the bore size. This can be an indication of wear because of a loose fit.Connecting rod bearings are available with 0.63 mm (0.025 inch) and 1.27 mm (0.050 inch) smaller inside diameter than the original size bearing. These bearings are for crankshafts that have been ground.Main Bearings
Main bearings are available with a larger outside diameter than the original size bearings. These bearings are used for the cylinder blocks with the main bearing bore that is made larger than the bores' original size. The size that is available has a 0.63 mm (0.025 inch) outside diameter that is larger than the original size bearings. These bearings are available with a standard inside diameter. Also, these bearings are available with a 0.63 mm (0.025 inch) inside diameter for crankshafts that have been ground.Main bearings are available with a smaller inside diameter than the original size bearings. These bearings are used for the cylinder blocks with a crankshaft that is made smaller than the crankshaft's original size. The size that is available has a 0.63 mm (0.025) and 1.27 mm (0.050 inch) inside diameter that is smaller than the original size bearings. These main bearings are for crankshafts that have been ground.Cylinder Block
If the main bearing caps are installed without bearings, the bore in the block for the main bearings can be checked. Tighten the nuts that hold the caps to the torque that is shown in the Specifications, "Cylinder Block". Alignment error in the bores must not be more than 0.08 mm (.003 inch). Refer to Special Instruction, SMHS7606 for instructions on the use of 1P-4000 Line Boring Tool Group .The 1P-3537 Dial Bore Gauge Group can be used to check the size of the bores. The Special Instruction, GMGO0981 is with the group.
Illustration 3 g00294303
1P-3537 Dial Bore Gauge Group Projection Of Cylinder Liners
Note: This procedure alleviates the need for the "H" bar to hold down liners during liner projection measurements.
Table 1
Tools Needed    
Part Number     Part Name     Quantity    
8T-0455     Liner Projection Tool Group     1    
Illustration 4 g00294304
Liner projection components (1) Bolt. (2) Washer. (3) Washer. (4) Spacer plate. (5) Block. (6) Cylinder liner.
Illustration 5 g00533892
Table 2
Components that are needed    
Item     Part Number     Description     Quantity For One Cylinder     Quantity For Six Cylinders    
1     7H-3598     Bolt   &nb