5032645 JOHNSON BOLT

Table 1
Required Tools
Tool Part Number Part Description Qty
A - M12 by 100 mm Guide Studs 2
B - M8 by 50 mm Set Screw 4
C - M10 x 1.25 by 50 mm Set Screw 1
D - Retaining Ring Pliers 1 Start By:
Remove the crankshaft position sensor. Refer to Disassembly and Assembly, Crankshaft Position Sensor - Remove and Install for the correct procedure.
Remove the electric starting motor. Refer to Disassembly and Assembly, Electric Starting Motor - Remove and Install for the correct procedure.
Remove the flywheel. Refer to Disassembly and Assembly, Flywheel - Remove for the correct procedure.
Remove the crankshaft rear seal. Refer to Disassembly and Assembly, Crankshaft Rear Seal - Remove and Install for the correct procedure.
If necessary, remove the accessory drive. Refer to Disassembly and Assembly, Accessory Drive - Remove and Install for the correct procedure.
Remove the engine oil pan. Refer to Disassembly and Assembly, Engine Oil Pan - Remove and Install for the correct procedure.
If necessary, remove the bracket for the Clean Emissions Module (CEM) for (Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF). Refer to Disassembly and Assembly, Clean Emissions Module (Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF) - Remove and Install for the correct procedure.
Illustration 1 g06154495
Bolt (2) "M8 x 1.25"
Bolts (3) "M12 x 1.75"
Illustration 2 g06154510
Current flywheel housing has four jacking points, later versions of the flywheel housing may have three jacking points.
Attach a suitable lifting device to flywheel housing (1). The weight of the flywheel housing is approximately 40 kg (88 lb).
Remove bolt (2) from flywheel housing (1).
Remove bolts (3) from Position (W).
Install Tooling (A) in Position (W).
Remove the remaining bolts from flywheel housing (1).
All jacking points in flywheel housing (1) must be used. Failure to use all the jacking point in the flywheel housing could result in damage to the flywheel housing.
Install Tooling (B) in the jacking points in Positions (X) in flywheel housing (1).
Evenly apply a half turn on each of Tooling (B) in a clockwise rotation to jack flywheel housing (1) from the dowels. Failure to apply an even turning motions to all the jacking points in the flywheel housing could result in damage to the flywheel housing.
Use the suitable lifting device to remove flywheel housing (1). Ensure that the crankshaft is not damage as the flywheel housing is removed.
Remove Tooling (B) from flywheel housing (1).
Illustration 3 g06154512
Do not remove the dowel (4) unless the dowel is damaged.
Inspect dowel hole (5) in the cylinder block for wear and damage.
Illustration 4 g06185943
If necessary, follow Step 12a through Step 12d to remove idler gear (9) from flywheel housing (1).
Use Tooling (D) to remove circlip (7) from flywheel housing (1).
Install Tooling (C) to threaded Hole (Y) in idler shaft (6).
Use Tooling (C) to assist removal idler shaft (6) from flywheel housing (1). Support the assembly of idler gear (9) as the idler shaft is removed from the flywheel housing.Note: Note the orientation of the idler gear for installation purposes.
Remove O-ring seal (8) (not shown) from idler shaft (6).Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A - M12 by 100 mm Guide Studs 2
D - Retaining Ring Pliers 1
E - International Products P-80 Emulsion Rubber Assembly Lubricant 1
F - Loctite 5900 1
Ensure that all components are free from wear or damage. If necessary, replace any component that is worn and damaged.
Clean the gasket surfaces of the flywheel housing and the cylinder block.
Illustration 5 g06186221
If necessary, follow Step 3a through Step 3d to install idler gear (9) to flywheel housing (1).
Install a new O-ring seal (8) (not shown) to idler shaft (6). Lubricate the O-ring seal with Tooling (E).
Install idler gear (9) into flywheel housing (1). Ensure that the idler gear is correctly orientated.
Install idler shaft (6) to flywheel housing (1). Ensure that cut out (10) in the idler shaft is correctly aligned with recess (11) in the flywheel housing.Note: Support the assembly as the idler shaft is installed to the flywheel housing.
Use Tooling (D) to install circlip (7) to flywheel housing