5034959 JOHNSON *GASKET, INTAKE MANIFOLD

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 9U-6198 Crankshaft Turning Tool 1
A(2) 9U-7336 Housing 1
5P-7305 Engine Turning Tool 1
B 230-6284 Timing Pin (Camshaft) 1
C 136-4632 Timing Pin (Crankshaft) 1
268-1966 Adapter 1
D 298-5564 T40 Torx Socket 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.Start By:
Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure.
Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Note: Either Tooling (A) can be used. Use the Tooling that is most suitable. Care must be taken in order to ensure that the fuel injection pump timing is not lost during the removal of the front gear group. Carefully follow the procedure in order to remove the gear group.
If the air compressor is equipped with a hydraulic pump, remove the hydraulic pump. Refer to Original Equipment Manufactures (OEM) for the correct procedure.
If the engine is equipped, with an air compressor remove the air compressor. Refer to Disassembly and Assembly, "Air Compressor - Remove" for the correct procedure.
If the engine is equipped with only a hydraulic pump, remove the hydraulic pump. Refer to the OEM for the correct procedure.
Illustration 1 g02048654
Remove plug (2) from the cylinder block. Remove O-ring seal (1) from the plug.
Use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure. Install Tooling (C) through Hole (W) in order to lock the crankshaft. Note: Do not use excessive force to install Tooling (C). Do not use Tooling (C) to hold the crankshaft during repairs.
Illustration 2 g03388958
Loosen nuts (4) on all rocker arms (5). Use Tooling (D) in order to loosen adjusters (3) on all rocker arms (5) until all valves are fully closed. Note: Failure to ensure that ALL adjusters are fully unscrewed can result in contact between the valves and pistons.
Illustration 3 g03389316
Install Tooling (B) through Hole (X) in camshaft gear (6) into the front housing. Use Tooling (B) in order to lock the camshaft in the correct position. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.
Illustration 4 g03389324
If the left-hand side of the engine is equipped, with a hydraulic pump remove the hydraulic pump. Refer to the OEM for the correct procedure to remove the hydraulic pump.
If necessary, remove bolts (10) from plate (9). Remove plate (9) and remove O-ring seal (8).
Remove circlip (15) and remove gear assembly (12) from front housing (7).
If necessary, follow Step 11.a through Step 11.b in order to disassemble gear assembly (21).
Remove circlip (14) from gear (12).
Place gear assembly (12) on a suitable support. Press bearing (13) from gear (12).
If necessary, remove bearing (11) from front housing (7). Refer to Disassembly and Assembly, "Housing (Front) - Remove" for the correct procedure.
Illustration 5 g03388971
Mark gear (6), gear (16), gear (17), and gear (18) in order to show alignment. Refer to Illustration 5. Note: Identification will ensure that the gears can be installed in the original alignment.
Remove camshaft gear (6). Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Ins