5001603 JOHNSON GEARCASE Assy, Complete

1. Turn the crankshaft until the timing mark (C) on the crankshaft gear (1) is in alignment with the timing mark (C) on camshaft gear (2).2. Make a mark on the teeth of the fuel pump drive gear and the idler gear in their engaged position at location (X). Make a mark on the engaged teeth of idler gear and camshaft gear at location (Y). This will give assistance in the correct timing of the camshaft for the fuel injection pump during crankshaft installation. 3. Fasten a hoist to the crankshaft.4. Remove the caps for the main bearings.5. Remove the crankshaft. Weight of the crankshaft is approximately 95 kg (210 lb).6. Remove the main bearings from the main bearing caps. Remove the crankshaft main bearings from the cylinder block. 7. Use Tool (A) to remove the crankshaft gear and the oil seal wear sleeve.Install Crankshaft
Install the bearings dry when the clearance checks are made. Put clean engine oil on the main bearings for final assembly.
Make sure the upper and lower halves of the main bearings are installed so the bearing tabs fit into the notch in the cylinder block and main bearing caps.
1. Clean the bearing surfaces in the cylinder block. Install the upper halves of the main bearings in the block.2. Heat the crankshaft gear to a maximum temperature of 315 °C (600 °F). Install the gear on the crankshaft. Fasten a hoist to the crankshaft and put the crankshaft in position in the cylinder block with all timing marks in alignment.3. Clean the bearing surfaces of the main bearing caps. Install the lower halves of the main bearings in the caps. When the bearing clearance is checked and the engine is in a vertical position, such as in the vehicle, the crankshaft will have to be lifted up and held against the upper halves of the main bearings to get a correct measurement with the Plastigage. The Plastigage will not hold the weight of the crankshaft and give a correct indication. If the engine is in a horizontal position, it is not necessary to hold the crankshaft up. Do not turn the crankshaft when the Plastigage is in position to check clearances. 4. Check the main bearing clearances with Plastigage (B) as follows: a. Put a piece of Plastigage (B) in position as shown.
Make sure the part number on the main bearing cap is toward the front of the engine and the number on the main bearing cap is the same as the number on the cylinder block on the left side of each main bearing cap.
Do not turn the crankshaft when Plastigage (B) is in position.b. Install the main bearing caps. Put 4C-5593 Anti-Seize Compound on the bolt threads and the face of the washers and install the bolts. Tighten the bolts to a torque of 40 4 N m (30 3 lb ft).
Do not use an impact wrench to tighten the bolts the additional 90 degrees (1/4 turn).
c. Put a mark on each bolt and main bearing cap, then tighten the bolts 90 degrees (1/4 turn more).d. Remove the main bearing caps. Remove Plastigage (B) and measure the width of the Plastigage. The main bearing clearance must be 0.076 to 0.165 mm (.0030 to .0065 in). The maximum permissible clearance with used bearings is 0.25 mm (.010 in). 5. Put clean oil on thrust bearing (3) for the No. 7 main bearing. Install the thrust bearing with the identification "BLOCK SIDE" toward the cylinder block. Engines that have a spacer plate have a thrust bearing that has a tab on it and must be installed with the tabs of the thrust bearings in the machined area in the cylinder block. The tabs will not let the thrust bearings be installed backward.6. Install the main bearing caps and tighten the bolts as in Steps 4b and 4c. 7. Check the crankshaft end play with Tooling (C). The end play is controlled by the thrust bearings on the No. 7 main bearing. The end play must be 0.579 mm (.023 in) maximum0.122 mm (.005 in) minimum.End By:a. install pistons and connecting rodsb. install flywheel housingc. install timing gear cover