0385812 JOHNSON THROTTLE SHAFT

Table 1
Required Tools
Tool Part Number Part Description Qty
A 8T-0455 Liner Projection Tool 1
B 2P-8260 Cylinder Liner Installation Tool 1
C 486-1525 Lubricant 1 Regional alternatives of Tooling (C) are available at the following website:https://www.ipcol.com/assembly-lubricants/p80-emulsion
Note: The following procedure alleviates the need for the crossbar to hold the cylinder liners during cylinder liner projection measurements.
Table 2
Required Components
Item Part Number Part Description Quantity For One Cylinder Quantity For Six Cylinders
1 0S-1589 Bolt 6 26
2 2S-0736 Washer 6 26
3 8F-1484 Washer 6 26
4 7K-1977 Washer 6 26
Illustration 1 g00478433
Install clean cylinder liners without the rubber seals or the filler band. Install the spacer plate gasket and the clean spacer plate.
Illustration 2 g00478745
Install the bolts and the washers that are illustrated in Table 2. Install the bolts and the washers in the holes that are indicated with an "X" that are shown in illustration 2. Tighten the bolts to a torque of 95 N m (70 lb ft).
Use Tool (A) to measure the liner projection at four positions. Place Tool (A) next to each of the hold down bolts and record the measurement. Record the measurements for each cylinder. Add the measurements for the individual cylinders together. Divide the sum by the number of cylinders in order to find the average.
Table 3
Specifications
Liner Projection 0.033 mm (.0013 inch) to 0.175 mm (.0069 inch)
Maximum Variation in Each Cylinder 0.051 mm (.0020 inch)
Maximum Average Variation Between Adjacent Cylinders 0.051 mm (.0020 inch)
Maximum Variation Between All Cylinders 0.102 mm (.0040 inch)
If the liner projections are out of specification, try rotating the cylinder liner. If the liner projections are out of specifications, try installing the cylinder liner in a different cylinder bore to improve the measurements.Note: Do not exceed the maximum liner projection of 0.175 mm (0.0069 inch). Cracking in the flange of the cylinder liner results from excessive cylinder liner projection measurements.
With the proper liner projection, mark the liners in the proper position and set the liners aside.
Lubricate the O-ring seals, the cylinder liner, and the upper filler band before installation.Note: If the lower O-ring seals are black in color, apply liquid soap on the lower O-ring seals and the cylinder block. Use clean engine oil on the upper filler band.Note: If the lower O-rings are brown in color, apply engine oil on the lower O-ring seals, the cylinder block, and the upper filler band.
Illustration 3 g00478753
Apply Tooling (C) on the bottom liner bore in the cylinder block, on the grooves in the lower liner and on O-ring seals (4) on the cylinder liner.
Lubricate filler band (5) with clean engine oil and install filler band (5) on cylinder liner (6). Install the cylinder liner (6) into the engine block immediately after lubricating the cylinder liner. This helps to prevent swelling of the filler band.
Illustration 4 g00478920
Ensure that the mark on the cylinder liner is in alignment with the mark on the cylinder block. Use Tool (B) to press the cylinder liner into position.
Repeat 1 through 6 for each of the cylinder liners.End By:
Install the Pistons and Connecting Rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Install".
Install the Engine Oil Pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install".
Install the cylinder head. Refer to Disassembly and Assembly, "Spacer Plate - Remove and Install".