5006715 JOHNSON PISTON, 0.020 in. O.S. , Stbd

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 230-6283 Timing Pin (Crankshaft) 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.Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Ensure that wiring harness are correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness convoluting.
Illustration 1 g03675398
Illustration 2 g03673295Note: The shaft of the fuel injection pump will sit in one of six angular rest positions. It is necessary to set the fuel injection pump shaft to the position of 83 degrees before the Top Dead Centre Position on Number one cylinder.
If necessary, follow Step 1.a through Step 1.d in order to install the bracket to the fuel injection pump.
Position fuel injection pump (13) in a suitable stand.
Position bracket (30) onto fuel injection pump (13). Ensure that the bracket is correctly orientated.
Install bolts (31) hand tight.
Tighten bolts (31) to a torque of 22 N m (195 lb in).
If necessary, install flow control valve (10). Refer to Disassembly and Assembly, "Flow Control Valve - Remove and Install" for the correct procedure.
Illustration 3 g03673303
The Angle (Y) should be 83 degrees. The Angle (Z) should be 18 degrees
Illustration 4 g03673373
If necessary, use Tooling (A) in order to rotate the crankshaft so that number one piston is in the Top Dead Centre Position on the compression stroke.
If necessary, install Tooling (B) in Position (X) in order to ensure that the crankshaft is in the correct position. Remove Tooling (B). Note: Do not use excessive force to install Tooling (B). Do not use Tooling (B) to hold the crankshaft during repairs.
Use Tooling (A) to rotate the crankshaft in a counter clockwise direction 80 degrees.
Install a new O-ring seal (24) to fuel injection pump (13).
Position key (32) onto fuel injection pump shaft (2) in the position shown in Illustration 3.
Illustration 5 g03674811
Illustration 6 g03673275
Illustration 7 g03674776
Carefully install fuel injection pump (13) to front housing (25). Ensure that the bore in front housing (25) is not damaged during the fuel injection pump is installation.
Install new bolts (26) to fuel injection pump (13) hand tight. Note: The fuel injection pump should be supported by hand as the bolts are installed.
Tighten bolts (26) to a torque of 44 N m (32 lb ft) in the sequence shown in Illustration 7.
Position fuel injection pump gear (1) onto fuel injection pump shaft (2). Ensure that key (32) aligns correctly with the fuel injection pump gear.
Install a new spring washer (4) (not shown) and install nut (3) hand tight.
Use a suitable tool to prevent the timing gears from rotating when tightening nut (3). Tighten the nut to a torque of 163 N m (120.22 lb ft).