0390768 JOHNSON WATER PUMP REPAIR KIT

Table 1
Required Tools
Tool Part Number Part Description Qty
A 448-5087 Barring Tool (1) 1
B 1P-1861 Retaining Ring Pliers 1
C 271-0498 Expander Ring 1
D 485-8003 Tool As 1
E - Bel-Ray Molylube 67700(2) -
(1) The 9S-9082 Engine Turning Tool is alternative tooling.
(2) Refer to the following link to order molylube specified above - www.belray.com.
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.
Illustration 1 g01004841
Use Tooling (C) to install the piston rings onto the piston.
For the oil control ring, ensure that the ends of the spring are 180 degrees from the ring gap. The white portion of the spring must be visible at the ring gap.
Install the intermediate ring with the side marked "UP-2" toward the top of the piston.
Install the top ring with the side marked "UP-1" toward the top of the piston.
After the rings are installed, rotate the rings so that the gaps are spread apart by 120 degrees. Orient the oil control ring gap toward the bore for the piston pin.
Illustration 2 g01006026
Place the piston crown into the piston skirt. Use clean engine oil to coat the bore of piston (3), piston pin (4), and the piston pin bearing in connecting rod (5). Position connecting rod (5) inside piston (3). Insert piston pin (4) through piston (3) and the bearing.
Illustration 3 g02142776
Use Tooling (B) to install the retaining rings. Orient the retaining ring gaps toward the top of piston (3).
Apply clean engine oil to the cylinder liner bore, to the piston rings, and to the outer surface of the piston.Note: Ensure that the connecting rod and pistons are installed in the correct cylinder.
Illustration 4 g02142782
Use Tooling (A) to rotate the crankshaft until the connecting rod journal is at the bottom center.
Use Tooling (D) to install the piston in the cylinder liner.Note: Be careful not to damage the cylinder liner or the crankshaft journal during the installation of the piston and the connecting rod.
Illustration 5 g00913801
Illustration 6 g06117839
Section view of connecting rod showing torque sequence. Chamfer (7) and dowel (8) can be used to reference orientation.
Install the upper half of the connecting rod bearing on the connecting rod. Ensure that the connecting rod bearing is installed so that the bearing tab fits into the notch in the connecting rod. Coat the connecting rod bearing with clean engine oil. Position the connecting rod onto a journal of the crankshaft.
Install the lower half of the connecting rod bearing on connecting rod cap (2). Ensure that the connecting rod bearing is installed so that the bearing tab fits into the notch in the connecting rod cap. Coat the connecting rod bearing with clean engine oil.Note: The number that is on the side of the connecting rod caps must be installed next to the corresponding number that is on the side of the connecting rod. Install the chamfered side of the connecting rod cap next to the thrust surface of the crankshaft.Note: Reman connecting rods are not numbered for the cylinder position.
Apply Tooling (E) to the threads, the shank, and the seat of bolts (1).
Place connecting rod cap (2) into position. Install bolts (1). Use the following procedure to tighten the bolts:
Tighten Bolt (X2) and Bolt (X4) to a torque of 90 5 N m (65 4 lb ft).
Tighten Bolt (X1) and Bolt (X3) to a torque of 90 5 N m (65 4 lb ft).
Tighten Bolt (X1) and Bolt (X3) again to a torque of 90 5 N m (65 4 lb ft).
Place an index mark on the bolts and the connecting rod cap. Tighten each bolt for an extra 90 5 degrees (1/4 turn).
Rotate the crankshaft to ensure that the crankshaft turns freely.End By:a. Install the piston cooling jets.b. Install the cylinder head.