819240A 2 Force CYLINDER ASSEMBLY (PAINTED)

Illustration 1 g06326972
Rear view of engine
Illustration 2 g03155497
Cam gear bolt tightening sequence
Table 1
Item Qty Part Specification Description
1 1 230-6202 Idler Gear As Before assembly, lubricate the shaft, the bearing bore, and the thrust faces with clean engine oil.
After installation, bore in the 224-9664 Bushing is 71.035 0.013 mm (2.7967 0.0005 inch).
Installation depth of the bushing is 2.6 0.5 mm (0.10 0.02 inch).
2 6 5B-0213 Bolt Torque to 55 10 N m (41 7 lb ft).
3 1 245-3804 Bolt Torque to 55 10 N m (41 7 lb ft).
4 12 6J-3913 Bolt Tighten bolt in the sequence 1, 4, 2, 5, 3, 6, 1, 4 as per Illustration 2 to 240 40 N m (177 30 lb ft).
5 2 331-6188 Camshaft Gear As Before assembly, lubricate the shaft, the bearing bore, and the thrust faces with clean engine oil.
With the number one piston in the top dead center position, align the timing marks. The mark on the camshaft gear must be in alignment with the mark in the rear housing.
6 1 185-1497 Idler Gear As Before assembly, lubricate the shaft, the bearing bore, and the thrust faces with clean engine oil.
After installation, bore in the 224-9664 Bushing is 71.035 0.013 mm (2.7967 0.0005 inch).
Installation depth of the bushing is 2.6 0.5 mm (0.10 0.02 inch).
7 4 1A-2029 Bolt Torque to 55 10 N m (41 7 lb ft).
8 1 226-6036 Idler Gear As Before assembly, lubricate the shaft, the bearing bore, and the thrust faces with clean engine oil.
With the number one piston in the top dead center position, align the timing marks. The mark on the idler gear must be in alignment with the mark on the crankshaft gear (9).
After installation, bore in the 226-6052 Bushing is 88.090 0.013 mm (3.4681 0.0005 inch).
Installation depth of the bushing is 3.2 0.5 mm (0.13 0.02 inch).
9 1 228-5813 Crankshaft Gear As Before assembly, lubricate the shaft, the bearing bore, and the thrust faces with clean engine oil.
Illustration 3 g06327033
Table 2
Item Qty Part Specification Description
10 1 224-1220 Plate Install the plate with the side marked "OUT" away from the gear face.
Thickness is 8.0 0.5 mm (0.31 0.02 inch).
11 8 7B-3235 Bolt Torque to 135 20 N m (100 15 lb ft).
12 2 117-8801 O-Ring Seal Before assembly, lubricate the bore lightly with the lubricant that is being sealed.
13 2 5P-8429 O-Ring Seal Before assembly, lubricate the bore lightly with the lubricant that is being sealed.
14 2 5F-7403 Lockwasher Torque to 406 68 N m (299 50 lb ft) and bend the tab on the lock which aligns with a nut slot.
15 2 5F-7404 Bearing Locknut
16 1 229-1663 Thrust Plate Install the thrust plate with the side marked "OUT" away from the gear face.
Thickness is 6.35 0.25 mm (0.250 0.010 inch).
17 1 4N-0848 Wear Sleeve Before assembly, lubricate the sleeve inner diameter with Loctite® 620.