5031385 JOHNSON COTTER, VALVE

Table 1
Required Tools
Tool Part Number Part Description Qty
A 230-6284 Timing Pin (Camshaft) 1
B 136-4632 Timing Pin (Crankshaft) 1
268-1966 Adapter 1
C 298-5564 T40 Torx Socket 1
D 235-0032 Valve Lash Gauge Gp 1
E 8T-5096 Dial Indicator Gp 1
- Magnetic Base and Stand 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g03414056
Illustration 2 g03414057
Ensure that Tooling (B) is installed in Hole (Y) in the cylinder block. Use Tooling (B) in order to lock the crankshaft in the correct Position. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.
Ensure that Tooling (A) is installed into Hole (X) in camshaft gear (3).
Illustration 3 g03414059
Illustration 4 g03414060
Illustration 5 g03414061
Clean idler gear (3) and inspect the idler gear for wear and damage. Refer to Specifications, "Gear Group (Front)" for more information. If necessary, replace the idler gear.
Clean hub (11) and inspect the hub for wear and damage. Refer to Specifications, "Gear Group (Front)" for more information. If necessary, replace the hub.
Lubricate hub (11) with clean engine oil. Install hub (10) into idler gear (3). Ensure that oil Hole (Z) is position as shown in the Illustration 4. Ensure that the timing marks are toward the front of the idler gear.
Align the timing marks on idler gear (3), camshaft gear (5), fuel injection pump gear (4). Refer to the Illustration 5. Install the assembly of idler gear (3) and hub (11).
Clean plate (9) and inspect the plate for wear and damage. If necessary, replace the plate.
Lubricate plate (9) with clean engine oil. Align the holes in plate (9) with the holes in hub (11). Install the plate in the original orientation. Note: Ensure that the identification mark TOP is upward.
Install bolts (10) hand tight
Remove Tooling (A) and Tooling (B). Note: Ensure that timing marks are aligned, before removing the Tooling (A) and Tooling (B).
Tighten bolts (10) to a torque of 44 N m (32 lb ft).
Illustration 6 g01996554
Position a new O-ring seal (1) onto plug (2). Install the plug to the cylinder block and tighten the plug to a torque of 21 N m (186 lb in).
Use Tooling (E) in order to check the end play for the idler gear. Refer to Specifications, "Gear Group (Front)" for more information.
Use Tooling (E) in order to check the backlash between the idler gear and the camshaft gear. Refer to Specifications, "Gear Group (Front)" for more information.
Use Tooling (E) in order to check the backlash between the idler gear and the crankshaft gear. Refer to Specifications, "Gear Group (Front)" for more information.
Use Tooling (E) in order to check the backlash between the idler gear and the fuel injection pump gear. Refer to Specifications, "Gear Group (Front)" for more information.
Lightly lubricate all of the gears with clean engine oil.
Illustration 7 g03378711
Use Tooling (D) in order to check the valve lash. Refer to System Operation, Testing and Adjusting, "Engine Valve Lash - Inspect/Adjust" for more information.
If necessary, use Tooling (D) and Tooling (C) in order to adjust the valve lash. Refer to System Operation, Testing and Adjusting, "Engine Valve Lash - Inspect/Adjust" for the correct procedure. End By:
Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure.
Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure.