0284481 JOHNSON ENGINE COVER ASSY., 115

START BY:a. remove air compressorb. remove alternatorc. remove air conditioning compressord. remove fan and fan drivee. remove oil pan
View From Under Machine1. Remove bolt (1) and lower half of mount assembly (2) from the machine.
View From Under Machine2. Put tooling (A) and wooden blocks in position under the engine as shown. Raise the engine just enough so that there is no weight on the front support.3. Remove the bolt and nut that hold clip (6) to the strap.4. Remove bolts (3), oil pick-up tube (5) and the gasket from oil pump (4). 5. Remove bolts (7), (8), (9) and support (10) from the timing gear cover. 6. Remove tube assembly (12), and loosen hose clamp (11). 7. Remove two bolts (16), and disconnect elbow (15) from the timing gear cover.8. Remove the bolt, and disconnect clip (13) from the timing gear cover.9. Use tooling (B) to remove fuel filter (14) from the fuel filter base. 10. Remove bolts (18) and nuts (17) that hold the timing gear cover to the plate on the left side of the machine. 11. Remove bolts (22) that hold the timing gear cover to the plate on the right side of the machine.12. Remove the air conditioner compressor mounting plate and adjusting rod from the front of the timing gear cover.13. Remove two bolts (19) that hold bracket (20) to plate (21). 14. Fasten tooling (C) and a hoist to the timing gear cover as shown.15. Remove the bolts from the front of the timing gear cover. Weight of the timing gear cover is 43 kg (95 lb.). 16. Remove the water ferrule, seal and clamp from the timing gear cover. The water ferrule and seal (24) and clamp (23) are located at the top of the timing gear cover on the backside as shown. The following steps are for installation of the timing gear cover.17. Inspect the condition of water ferrule and seal (24), and make a replacement if needed. Put water ferrule and seal (24) in position with the adjusting screw of hose clamp (23) toward the top and approximately 45° to the right of vertical centerline as seen from the front of the engine. Make sure the seal is installed all the way into the counterbore.18. Clean the old gasket from the contact surfaces of the timing gear cover and timing gear plate.19. Install a new gasket. Cut the gasket even with the bottom face of the cylinder block. Put 5H2471 Cement on the bottom of the gasket where it makes contact with the gasket for the oil pan.20. Fasten tooling (C) and a hoist to the timing gear cover as shown.21. Put the timing gear cover in position on timing gear plate. Make sure the gear on the engine oil pump is engaged with the crankshaft gear as the timing gear cover is installed.22. Install bolts (22) that hold the timing gear cover to the plate on the right side of the machine.23. Install two bolts (19) that hold bracket (20) to plate (21).24. Install air conditioner compressor mounting plate and adjusting rod on the front of the timing gear cover.25. Install bolts (18) and nuts (17) that hold the timing gear cover to the plate on the left side of the machine.26. Put elbow (15) and the gasket in position. Install bolts (16) that hold it to the timing gear cover.27. Put clip (13) in position on the timing gear cover. Install the bolt that holds it in place.28. Install fuel filter (14) according to the directions on the filter. See the Maintenance Guide for the correct service intervals.29. Install tube assembly (12) between the timing gear cover and cylinder head assembly. Tighten hose clamp (11).30. Put engine front support (10) in position on the timing gear cover, and install the bolts that hold it in place. Tighten bolts (7) to a torque of 55 7 N m (41 5 lb.ft.). Tighten bolts (8) and (9) to a torque of 90 15 N m (65 11 lb.ft.).31. Put the gasket and oil pick-up tube (5) in position on the oil pump, and install the bolts that hold it.32. Install the bolt and nut that hold clip (6) to the strap.33. Lower the engine with tooling (A) until the engine front support makes contact with the upper half of the engine mount assembly. Remove tooling (A) from the machine.34. Put the lower half of mount assembly (2) in position, and install bolt (1).END BY:a. install oil panb. install fan and fan drivec. install air conditioning compressord. install alternatore. install air compressor