0122505 JOHNSON PISTON

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     150-3992     Timing Pin (1)     1    
150-3993 Timing Pin (2)     1    
B     171-1085     Tamper Resistant Tool Gp     1    
( 1 ) Tool (A) is required in order to install Bosch fuel injection pumps.
( 2 ) Tool (A) is required in order to install Dephi (Lucas) and Stanadyne fuel injection pumps.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g00808386
Typical example
Check the condition of O-ring seal (13) on fuel injection pump (12). If the seal is worn or damaged, use a new part for replacement.
Lightly lubricate O-ring seal (13) with clean engine oil. Install O-ring seal (13) on fuel injection pump (12) .
The No. 1 cylinder must be at the top center position on the compression stroke before the fuel injection pump is installed. If the crankshaft needs to be rotated, the fuel injection pump must be mounted temporarily or the loose gear could cause damage to the front housing.
Illustration 2 g00808376
Typical example
Put fuel injection pump (12) in position on the engine. Ensure that the timing gear is aligned with the hub of fuel injection pump (12). Install three flange nuts (11) and tighten the flange nuts to a torque of 28 N m (21 lb ft).
Illustration 3 g00808370
Typical example
Position gear (9) on the shaft of the fuel injection pump.Note: Some fuel injection pumps are installed with tamper proof bolts. Tool (B) may be necessary in order to install the tamper proof bolts.
Put the timing gear plate in position and install four bolts (3). Tighten the four bolts finger tight.Note: The fuel injection pump gear will only fit in one position. Install the gear with the letters "C" and "M" facing away from the engine.
Illustration 4 g00808245
Typical example
Loosen locking screw (2) (if equipped) until locking spacer (1) moves freely. Move locking spacer (1) into position (A). Tighten locking screw (2) to a torque of 10 N m (7 lb ft).Note: The location of Tool (A) for Bosch fuel injection pumps will be located toward the top of the fuel injection pump. The location of Tool (A) for Dephi (Lucas) and Stanadyne fuel injection pumps will be located toward the bottom of the fuel injection pump.
Install Tool (A) through hole (6) in the timing gear and hole (7) in the hub. Push Tool (A) into position in hole (8) in the fuel injection pump body. If Tool (A) can be fully seated, the fuel injection pump timing is correct. No resistance should be felt when the timing pin is inserted into hole (8) of the fuel injection pump body.
The fuel injection pump may be supplied with the fuel injection pump shaft in the locked position. The drive shaft of the fuel injection pump must not be rotated without the spacer in position under the locking screw. Damage to the drive shaft of the fuel injection pump will result.
When the timing plate is installed, rotate gear (9) by hand in a counterclockwise direction in order to remove the backlash between gear (9) and the idler gear. Do not rotate the crankshaft or the fuel injection pump shaft. Tighten bolts (3) to a torque of 28 N m (21 lb ft).
Remove Tool (A) from the fuel injection pump gear.End By:
Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install".
Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install".