5000529 JOHNSON DECAL SET

Table 1
Required Tools
Tool Part Number Part Description Qty
A 6V-6080 Torque Multiplier Gp 1
5P-1748 Socket 1
4C-9451 Rear Idler Gear Wrench 1
4C-9452 Rear Idler Gear Wrench 1
B 9U-5932(1) Torque Wrench Extension 1
1P-2382(2) Wrench Adapter 1
C 4C-5593 Anti-Seize Compound -
(1) This tool is used on later models.
(2) This tool is used on earlier models.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g00636750
Earlier
Illustration 2 g00610687
Later
Illustration 3 g01303614
Earlier
Illustration 4 g00610685
Later
Note: The rear housing was removed for illustrative purposes only.
If the bearing was removed from gear (26), install the bearing in the gear. The bearing must be 3.0 0.5 mm (0.12 0.02 inch) below the surface of the side of the gear that has the smaller shoulder.
Place gear (17) in position on other gear (26). Install the bolts.
Attach a suitable lifting device to gear (17). The weight of gear (17) and other gear (26) is approximately 55 kg (121 lb).
Place the following components in position on shaft (24): gear (17), other gear (26) and retainer (21). Install bolts (18). Do not tighten the bolts at this time.
Attach a suitable lifting device to gear (17). The weight of the gear assembly is approximately 85 kg (187 lb). Place gear (17) and shaft (24) in position in the rear housing through the camshaft drive gear opening.
Attach a suitable lifting device to gear (17) through the opening for the accessory drive in the rear housing. Disconnect the suitable lifting device from gear (17) through the camshaft drive gear opening.
Align the teeth on gear (17) with the teeth on the crankshaft gear. Place shaft (24) in position on the cylinder block. Install bolts (25). Refer to Specifications, "Gear Group (Rear)" for the correct torque.
Tighten bolts (18).
If the bearings were removed from gears (22), install the bearings in the gears. The bearings must be 3.0 0.5 mm (0.12 0.02 inch) below the flat surface of the gear. The inside diameter of the bearings should be 150.002 0.020 mm (5.9056 0.0008 inch) after installation.
Place gear (22) and retainer (23) in position on shaft (19). Install the bolts that hold these components in place.
Attach a suitable lifting device to gear (22). The weight of the shaft and gear (22) is approximately 41 kg (90 lb). Place the shaft and gear (22) in position on the cylinder block through the camshaft drive gear opening in the rear housing. Install bolts (20). Refer to Specifications, "Gear Group (Rear)" for the correct torque.
Repeat Step 10 and Step 11 for the other idler gear.
Illustration 5 g00610680
Attach a suitable lifting device to drive shaft (1). The weight of drive shaft (1) is approximately 40 kg (88 lb). Place spacer (16) in position on the end of drive shaft (1). This is done on earlier engines only.
Install drive shaft (1) and spacer (16). Align the dowel in drive shaft (1) with the dowel hole in camshaft segment (3). Install bolts (2). Tighten all of bolts (2) by hand.
Illustration 6 g00610676
Place plate (15) in position and install bolts (14).
Place plate (12) in position on drive shaft (1) and install bolts (13).
Illustration 7 g00610662
Be sure that camshaft timing pins (6) are installed in both camshafts.