0210985 JOHNSON OWNERS MANUAL, Ev.

Table 1
Required Tools
Tool Part Number Part Description Qty
B 125-0200 Camshaft Pilot As 2
C 125-0201 Camshaft Guide As 1
D 8T-3169 Crank Assembly 1
E 238-9586 Camshaft Drive Group 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g03856103
Installation procedure is the same for both the left side and right side camshafts.
Attach a suitable lifting device to the rear half of the camshaft. The weight of the rear half of the camshaft is approximately 38 kg (84 lb).
Attach a suitable lifting device to the front half of the camshaft. The weight of the front half of the camshaft is approximately 33 kg (73 lb).
Install spacer (25) and the rear half of the camshaft onto the front half of the camshaft. Install bolts (26) and tighten to a torque of 55 7 N m (41 5 lb ft). Note: Ensure that the camshafts are assembled according to the marks on the ends of the camshafts. If the dowel was removed from the front half of the camshaft, install the dowel. Install the dowel to 22 0.5 cm (9 0.20 inch) from the surface of the camshaft.
Illustration 2 g01123198
Install Tooling (C) on the front housing. Do not tighten the bolts on Tooling (C). Note: Tooling (C) can be installed on the flywheel housing in order to install the camshaft from the rear of the engine.
Install Tooling (B) on the ends of the camshaft. Install Tooling (D) on Tooling (B) which is installed on the front of the camshaft.
Ensure that the camshaft and the camshaft bearings are clean. Place clean engine oil on the lobes and the journals of the camshaft. Also place clean engine oil on the camshaft bearings.
Rotate the camshaft and insert the camshaft in the engine. Position the camshaft in the engine until Tooling (B) is in the front camshaft bearing. Rotate the camshaft in order to align Tooling (C) and the camshaft bores. Tighten the bolts for Tooling (C).
Rotate the camshaft and insert the camshaft into the engine. Remove Tooling (B) from the camshaft. Remove Tooling (C) from the front housing.
Illustration 3 g03856042
Install thrust washer (22), plate (24), and bolts (23).
If the camshaft is out of time more than 18 degrees (approximately 1/2 of the timing pin is out of the groove), the valves can make contact with the pistons. This will cause damage to the engine. Refer to Testing and Adjusting, "Camshaft Timing" for more information.
Illustration 4 g03856567
Remove bolt (38), plate (36), and timing pin (37).
Turn the camshaft until the timing pin can be installed through the cylinder block and into the groove that is in the camshaft. Refer to Testing and Adjusting, "Camshaft Timing" for more information.
Illustration 5 g03856588
Remove bolts (40), cover (41), and plug (39).
Install one bolt (40) into the flywheel housing through the hole for plug (39). Use Tooling (E) and a ratchet to turn the flywheel until bolt (40) can be install through the hole and into the flywheel. Doing so will position the No. 1 cylinder at the top dead center. Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston" for more information.
Illustration 6 g03855987
Use the following procedure in order to install camshaft drive gear (21).
Clean the taper of the camshaft and the tapered bore of the camshaft gear with a lint free cloth saturated with solvent to remove oil. Clean the parts again with a lint free alcohol wipe in order to remove any residue. The alcohol wipe will be dirty after cleaning the parts. Clean the parts again with a lint free alcohol wipe until no residue is left on the alcohol wipe. Note: The camshaft and the tapered bore of the camshaft gear must be clean, dry, and free of residue before assembly.
Ensure that the camshaft timing pins and the timing pin for the flywheel are installed.
Place camshaft drive gear (21) in position. Remove the backlash by rotating the gears in the opposite direction of the camshaft rotation. Note: For "Standard Rotation" engines, turn the camshaft drive gears COUNTERCLOCKWISE. For "Reverse Rotation" engines, turn the camshaft drive gears CLOCKWISE.