0385531 JOHNSON COVER ASSEMBLY

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 9U-6198 Crankshaft Turning Tool 1
A(2) 5P-7306 Housing 1
5P-7305 Engine Turning Tool 1
B 364-9107 Timing Pin
(Fuel Injection Pump) 1
C 230-6284 Timing Pin (Camshaft) 1
D 136-4632 Timing Pin (Crankshaft) 1
268-1966 Adapter 1
E 298-5564 T40 Torx Socket 1
F 9U-7324 Indicator Bracket 1
7H-1942 Dial Indicator 1
3S-3268 Indicator Contact Point 1
7H-1940 Universal Attachment 1
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center for No. 1 Piston" for the correct procedure.
Illustration 1 g02491276
Illustration 2 g01996475
Ensure that Tooling (D) is installed in Hole (W) in the cylinder block. Use Tooling (D) 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 (C) is installed into Hole (X) in camshaft gear (3).
Use Tooling (B) in order to lock the fuel injection pump gear in the correct position. Refer to Disassembly and Assembly, "Fuel Injection Pump - Remove" for the correct procedure.
Illustration 3 g01996477
Illustration 4 g01996478
Illustration 5 g01996576
Clean idler gear (4) 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 (9) and inspect the hub for wear and damage. Refer to Specifications, "Gear Group (Front)" for more information. If necessary, replace the hub.
Lubricate hub (9) with clean engine oil. Install hub (9) into the recess in the front housing. Ensure that oil Hole (Z) is to the top of the hub.
Install idler gear (4) onto hub (9). Ensure that the timing marks are toward the front of the idler gear.
Align the timing mark on idler gear (4) with the timing mark on camshaft gear (3), fuel injection pump gear (10) and crankshaft gear (11). Refer to the Illustration 5. Install the assembly of idler gear (4) to hub (9).
Clean plate (8) and inspect the plate for wear and damage. If necessary, replace the plate.
Lubricate plate (8) with clean engine oil. Align the holes in plate (8) with the holes in hub (9). Install the plate in the original orientation. Note: Ensure that the identification mark TOP is upward.
Install bolts (7). Tighten the bolts to a torque of 44 N m (32 lb ft).
Remove Tooling (B), Tooling (C), and Tooling (D). Note: Ensure that timing marks are aligned, before removing the Tooling (B), Tooling (C), and Tooling (D).
Use Tooling (F) in order to check the end play for the idler gear. Refer to Specifications, "Gear Group (Front)" for more information.
Use Tooling (F) 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 (F) 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 (F) 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.
Failure to ensure that the crankshaft is set in the safe position will result in interference between the pistons and the valves. Interference between the pistons and the valves will result in damage to the engine.
Use Tooling (A) in order to rotate the crankshaft in a clockwise direction and position