0392133 JOHNSON STARTER MOTOR ASSY.

Table 1
Required Tools
Tool Part Number Part Description Qty
A 9S-9082 Engine Turning Tool 1
B 1P-1861 Retaining Ring Pliers 1
C 6V-4020 Piston Ring Expander 1
D 5P-8639 Hydraulic Press 1
5P-9725 Hydraulic Cylinder 1
8F-0024 Hose Assembly 1
1P-2375 Connecting Coupler 1
1P-2376 Connecting Coupler 1
5P-8649 Adapter 1
6V-3043 Spacer 1
6V-3042 Adapter 1
2D-2825 Hydraulic Pump 1
5P-8640 Bar Clamp 1 Start By:
Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove".
Remove the piston cooling jets. Disassembly and Assembly, "Piston Cooling Jets - Remove and Install".
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Use Tooling (A) to turn the engine to access the bolts in the connecting rod cap.
Mark the cylinder number on each connecting rod and the corresponding connecting rod cap.Note: The front of the engine is opposite the flywheel end. The No. 1 cylinder is at the front of the engine on the right side. The No. 2 cylinder is on the left side.
Illustration 1 g00582418
Remove bolts (1) and connecting rod cap (2) from the connecting rod.
Remove the bearings from connecting rod cap (2) and the connecting rod.
Illustration 2 g00764667
Push piston (3) out of the cylinder block until the piston rings are out of the cylinder liner.
Remove piston (3) and the connecting rod assembly.
Illustration 3 g00764676
Use Tooling (B) to remove the retaining rings that hold piston pin (5).
Remove piston pin (5).
Remove piston (3) from connecting rod (4).
Illustration 4 g00764680
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, SEBF8059-01, "Procedure To Clean And Inspect 3500 Series Engine Pistons" for the correct procedure for cleaning the pistons.
Raise the temperature of connecting rod (3) to a temperature of 218° 40°C (425° 75°F).Note: Do not use a direct flame to raise the heat of the connecting rod.
Illustration 5 g00582422
Place spacer (14) in the base plate of Tooling (D). Place the connecting rod on the base plate.
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 adapter (12). Align the hole in adapter (12) with the hole that is in the base plate of Tooling (D).
Install bar clamp (13) and clamp pin (10).Note: The old bearing is pushed out while the new bearing is installed.
Position adapter (11) with the tapered side facing downward. The piston pin bearing joint must be aligned with the hole in adapter (12) and the hole in the base plate of Tooling (D).
Place pusher (7) on adapter (11).
Use Tooling (D) to push new piston pin bearing (8) into the connecting rod until adapter (11) contacts the connecting rod.
Remove the connecting rod and the old piston pin bearing from Tooling (D).
Measure the diameter of the bore after the piston pin bearing is removed. The bore should have a diameter of 70.380 0.010 mm (2.7709 0.0004 inch).
Refer to Special Instruction, SEHS7295-02, "Use Of Piston Pin Bearing Removal And Installation Tools" for more information.