0383493 JOHNSON SWITCH ASSEMBLY, Ignition

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     9S-9082     Engine Turning Tool     1    Start By:
Remove the engine oil pump.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01139029
Use Tooling (A) to turn the crankshaft until the connecting rod bearing caps are accessible.
Check connecting rod (3) and connecting rod caps (1) for identification and for the location.
Remove connecting rod cap bolts (2) and connecting rod cap (1) from connecting rod (3). Remove the lower half of connecting rod bearing (5) from connecting rod cap (1) .Note: This engine has fractured connecting rods. Fractured connecting rods must be handled with care. Use a soft faced hammer in order to tap the connecting rod cap, if necessary.Note: Do not place the fractured faces of the connecting rod cap on any surface. The connecting rod cap must be laid flat on the side in order to prevent damage to the fractured faces of the connecting rod cap.
Push connecting rod (3) away from the crankshaft. Remove the upper half of connecting rod bearing (4) from connecting rod (3) .Note: Do not damage the fractured faces of the connecting rod. Place a suitable protective cap on the ends of the connecting rod in order to prevent damage to the fractured faces of the connecting rod.Installation Procedure
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
The joint between the connecting rod and the connecting rod cap is produced by fracturing. The connecting rod assembly must be handled with care in order to avoid damage to the mating surfaces. The connecting rod assembly must be replaced if any damage occurs to the mating surfaces. New connecting rod assemblies come with the connecting rod caps bolted on the connecting rod.Use only a soft faced hammer to tap the connecting rod cap when separating the connecting rod cap from the connecting rod.Failure to use a soft faced hammer may result in damage to the fractured surfaces of the connecting rod assembly.
Use Tooling (A) to turn the crankshaft until the connecting rod bearing cap is accessible.
Illustration 2 g01139029
Note: Install the connecting rod bearings dry when clearance checks are performed. Apply clean engine oil to the connecting rod bearings for final assembly.
Remove the protective caps from the end of the connecting rod and install the upper half of connecting rod bearing (4). Ensure that the bearing tab engages with the slot in connecting rod (3) .
Pull the piston and connecting rod assembly onto the crankshaft.
Install the lower half of connecting rod bearing (5) into connecting rod cap (1). Ensure that the bearing tab engages with the slot in connecting rod cap (1) .Note: Do not place the fractured faces of the connecting rod cap on any surface. The connecting rod cap must be laid flat on the side in order to prevent damage to the fractured faces of the connecting rod cap.Note: Ensure that the number on the connecting rod cap matches the number on the connecting rod. Make sure that both of the numbers are located on the same side.
Install connecting rod cap (1) and connecting rod cap bolts (2) .
Check the bearing clearance. Refer to Disassembly and Assembly, "Bearing Clearance - Check".
Tighten connecting rod cap bolts (2) to a torque of 50 5 N m (37 3 lb ft).
Place an index mark on each connecting rod cap bolt (2). Tighten each bolt for an additional 90 5 degrees (1/4 turn).
Use Tooling (A) to rotate the crankshaft in order to ensure that the crankshaft turns freely.End By: Install the engine oil pump.