96220-50080 Honda ROLLER (5X8)

Start By:a. remove crankshaft rear seal and wear sleeve *b. remove starting motors (electric)c. remove oil pand. remove engine*This operation is located in the Disassembly & Assembly, 3500B Diesel Engines module, SENR6564 1. Remove covers (1) and the gaskets from flywheel housing (4). 2. Remove the bolt and ring (2) from the flywheel housing. 3. Remove the bolt and plate (5) from camshaft drive gear (3). 4. Put the three washers from Tooling (A) behind plate (5) and install the bolt and plate (5).
Do not apply more than 51675 kPa (7500 psi) pressure to 1P-0820 Hydraulic Puller. 8B-7559 adapters are rated at 6 1/2 ton each and 1P-0820 Hydraulic Puller is rated at 17 ton at 68900 kPa (10000 psi). If too much pressure is applied, the gear may be damaged.
5. Install Tooling (A) on camshaft drive gear (3). Apply 51675 kPa (7500 psi) to the puller. If necessary, use a hammer to impact the head of the puller screw on Tooling (A). This should break the gear free from the tapered end of the camshaft. Repeat procedure for on the remaining camshaft drive gear.6. Put stands or blocks under the rear of the engine block. The weight of the engine is approximately 6090 kg (13,400 lb.).7. Install Tooling (B) on the top of flywheel housing (4). Position a suitable lifting device through Tooling (B). Secure the lifting device to a hoist. 8. Remove all bolts that fasten flywheel housing (4) to the engine block.
Dowel pins are used for the correct alignment and positioning of flywheel housing (4) to the engine block. Removal of the locating dowel pins may help to free flywheel housing (4) from the engine block.
9. Remove flywheel housing (4) from the engine. The weight of the flywheel housing is 210 kg (454 lb.). The following steps are for the installation of the flywheel housing. Also refer to Engine Specifications Manual for additional information.10. Use 6V-1541 Quick Cure Primer to clean the mating surfaces of the flywheel housing and the cylinder block. Put 6V-6640 Sealant on the mating surfaces of the flywheel housing and cylinder block.11. Install Tooling (B) on the top of flywheel housing (4). Position a suitable lifting device through Tooling (B). Secure the lifting device to a hoist. Put flywheel housing (4) in position to the cylinder block.12. If the locating dowel pins were removed from flywheel housing (4) and the cylinder block, install the dowel pins. Make sure the dowel pins are properly seated. 13. Install the bolts for flywheel housing (4) in their respective locations. See the Installation Chart. Tighten the 1/2 in. - NC bolts to a torque of 135 15 N.m (100 11 lb. ft.). Tighten the 5/8 in. NC bolts to a torque of 270 25 N.m (200 18 lb. ft.).14. Remove Tooling (B).15. Put the camshaft timing pins in position. Put the timing bolt in the flywheel with number 1 piston at the compression stroke. Refer to the topic, Install Camshafts 3500B Diesel Engines, Disassembly & Assembly Manual. Be sure gear backlash is removed. 16. Put camshaft drive gear (3) in position and install the bolt and plate (5). Repeat this procedure for the remaining camshaft drive gear.17. Put ring (2) in position to the camshaft and locating dowel. Install the washer and bolt for timing ring (2).18. Use the following steps to seat the camshaft gears to the tapered ends of the camshafts: a. Tighten the bolt holding timing ring (2) to a torque of 360 50 N.m (265 35 lb. ft.).b. Use a soft hammer to hit the head of the bolt holding timing ring (2). This will help seat camshaft drive gear (3) the gear on the camshaft.c. Again tighten the bolt holding timing ring (2) to a torque of 360 50 N.m (265 35 lb. ft.). Put a mark on the bolt and timing ring (2).d. Repeat Steps b. and c. until the bolt holding timing ring (2) no longer moves (the marks stay aligned) after reaching the proper torque.e. Repeat Steps a. through d. to seat the remaining camshaft drive gear (3) located beneath the bolt and plate (5).20. Remove the timing pins from the camshafts and the flywheel.21. Install covers (1) in their respective positions.End By:a. install engineb. install oil panc. install starting motors (engine)d. install crankshaft rear seal and wear sleeve **This operation is located in the Disassembly & Assembly, 3500B Diesel Engines module, SENR6564