0324384 JOHNSON CONNECTOR,Cable to throttle lever

Table 1
Required Tools
Part Number Part Description Qty
230-6283 Crankshaft timing pin 1
230-6284 Camshaft timing pin 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: The fuel injection pump shaft must remain locked until this procedure instructs you to unlock the fuel injection pump shaft.
If necessary, install the crankshaft gear. Refer to this Disassembly and Assembly Manual, "Crankshaft Gear - Remove and Install".
Thoroughly clean the housing (front).
Thoroughly clean all of the components and inspect all of the components of the front gear group. If necessary, replace any worn components and/or any damaged components of the front gear group.
Ensure that no. 1 piston is still at top dead center. Refer to Testing and Adjusting Manual, "Finding Top Center for No. 1 Piston".
Illustration 1 g01230060
Typical example
Install the camshaft gear (1). Refer to Disassembly and Assembly Manual, "Camshaft Gear - Remove and Install".
Install the idler gear (2). Refer to Disassembly and Assembly Manual, "Idler Gear - Remove and Install".
Ensure that the mesh of the idler gear (2) is correct with the camshaft gear (1).
Install the fuel injection pump gear (3) onto the fuel injection pump shaft. Ensure that the mesh of the fuel injection pump gear (3) is correct with the idler gear (2). Install the washer and the nut (6) finger tight.
Apply hand pressure to the fuel injection pump gear (3) in a counterclockwise direction in order to remove the backlash in the gears (1), (2), and (3). Tighten the nut (6) to a torque of 24 N m (18 lb ft).
Ensure that all of the timing marks on the gears (1), (2), and (3) are in alignment.
Illustration 2 g01230058
Typical example
In order to unlock the Delphi DP210 fuel injection pump shaft, loosen the locking screw (7) and move the washer (8). Tighten the locking screw (7) onto the washer (8) to a torque of 12 N m (9 lb ft).
Tighten the nut (6) to an increased torque of 90 N m (66 lb ft).
Remove the timing pins that are at positions (4) and (5). Refer to illustration 1.
Check the backlash value for the fuel injection pump gear (3). Refer to the Specifications Manual, "Gear Group (Front)" for further information.
Check the end play of the idler gear (2). Refer to this Disassembly and Assembly Manual, "Idler Gear - Remove and Install" and refer to the Specifications Manual, "Gear Group (Front)" for further information.
Check the backlash value for the idler gear (2). Refer to this Disassembly and Assembly Manual, "Idler Gear - Remove and Install" and refer to the Specifications Manual, "Gear Group (Front)" for further information.
Check the end play of the camshaft gear (1). Refer to this Disassembly and Assembly Manual, "Camshaft Gear - Remove and Install".
Check the backlash value for the camshaft gear (1). Refer to this Disassembly and Assembly Manual, "Camshaft Gear - Remove and Install" and refer to the Specifications Manual, "Gear Group (Front)" for further information.
Lightly lubricate each gear with clean engine lubricating oil. End By:
Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install".
Install the glow plugs. Refer to this Disassembly and Assembly Manual, "Glow Plugs - Remove and Install".
Install the rocker shaft. Refer to this Disassembly and Assembly Manual, "Rockershaft and Pushrod - Install".