0383690 JOHNSON GEARCASE ASSEMBLY, Complete

Start By:a. remove turbochargerb. remove timing gear cover and oil pumpc. remove valve lifters 1. Remove the plug from the fuel injection pump housing, and install timing pin (A).2. While the crankshaft is turned clockwise (as seen from the front of the engine), push on Tool (A) until it slides into the groove (slot) in the fuel injection pump camshaft.3. Remove tachometer drive adapter shaft (1). 4. Install Tooling (B) into the camshaft drive gear for the fuel injection pump. Turn the center bolt until the drive gear is free of the shaft. Remove Tooling (B).
Typical Example5. Remove thrust pin (2) that holds the camshaft in place from the rear of the cylinder block. 6. Remove camshaft (3) and the gears from the cylinder block as a unit. Be careful not to cause damage to the camshaft bearings or camshaft lobes. The camshaft gear can be removed from the camshaft if a replacement is necessary.Install Camshaft & Gears
1. Install the camshaft gear on the camshaft if it was removed. Heat the gear to a maximum temperature of 315°C (600°F). Put the gear in position on the camshaft. 2. Put 4C-5593 Thread Lubricanton the camshaft lobes. Install camshaft (3) and the gears as a unit. Make sure the timing marks on the crankshaft gear and camshaft gear are in alignment.
Typical Example3. Install thrust pin (2). Tighten the pin to a torque of 48 7 N m (35 5 lb ft). 4. Put gear (4) in position, and install tachometer drive adapter shaft (1). Tighten the shaft to a torque of 150 14 N m (110 10 lb ft).5. Install the timing gear cover and oil pump. See the topic, "Remove & Install Timing Gear Cover & Oil Pump" in this manual.6. Install the valve lifters. See the topic, "Remove & Install Valve Lifters" in this manual. 7. After the valve lifters and timing gear cover have been installed, check the timing as follows:a. Remove timing pin (A).b. Turn the crankshaft clockwise as seen from the front of the engine approximately 180 degrees. Install timing pin (A) again.c. While turning the crankshaft clockwise, push on timing pin (A) until it slides into the groove (slot) in the fuel injection pump camshaft.d. Remove the plug from the timing hole in the front cover and install a 5/16 -18 x 64 mm (2.5 in) Long Bolt(6). The cover bolt from hole (5) can be used. Check to make sure bolt (6) can be installed into the timing gear and is in the center of the timing hole. The camshaft for the fuel injection pump is now in correct time with the engine.e. Remove the bolt and install the plug. Remove timing pin (A) and install the plug. If the bolt cannot be installed in the hole of camshaft gear, the timing must be corrected as follows:a. With timing pin (A) installed, remove the tachometer drive adapter housing and shaft.b. Loosen the gear from the fuel injection pump camshaft. Turn the crankshaft clockwise approximately two full turns until bolt (6) can be installed. Install the bolt.c. Install the tachometer drive adapter shaft, and tighten it to a torque of 150 14 N m (110 10 lb ft). Install the adapter housing. Remove the bolt and timing pin and install the plugs. For more detailed information regarding the camshaft & gears, see the topic "Camshaft" in the Specifications Manual.End By:a. install valve liftersb. install timing gear cover and oil pumpc. install turbocharger