0449507 JOHNSON PLUNGER & DETENT ASSY.

Table 1
Required Tools
Tool Part Number Part Description Qty
A 207-5034 Stud Tensioner Tool Group 1
8T-3035 Hydraulic Line 1
8T-0820 Hydraulic Pressure Gauge 1
3S-6224 Electric Hydraulic Pump
(115 Volt 50/50 Hz) 1
8S-8033 Electric Hydraulic Pump
(230 Volt 50/60 Hz) 1
9U-6600 Hand Hydraulic Pump 1
B 4C-5593 Anti-Seize Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Clean the crankshaft.
Clean the crankshaft main bearings.
Illustration 1 g00588160
Clean the cylinder block.
If the studs were removed, tighten the studs (1) for the main bearing cap to a torque of 100 20 N m (75 15 lb ft).
Put the 50 mm (2 inch) plastic sleeves on the main bearing studs in order to prevent damage to the crankshaft during the removal procedure.
Put the upper halves (2) of the main bearings into position in the cylinder block. Ensure that the tab on the back of the bearing is engaged with the slot in the cylinder block.
Put clean engine oil on the bearings.
Be sure to identify the front of the crankshaft and the rear of the crankshaft. The front center hub of the crankshaft is stamped with "FRT".
The rear of the crankshaft is identified by three holes in the flange.
Position the crankshaft below the engine block. Fasten a lifting sling and a suitable lifting device to each end of the crankshaft. The weight of the crankshaft is approximately 2948 kg (6500 lb).
Raise the crankshaft into position in the upper half of the main bearing. Use a person on each end of the crankshaft in order to guide the crankshaft past the main bearing studs.
Remove the plastic sleeves from the main bearing studs.
Install the lower half of the main bearing in the Number 5 main bearing cap. Ensure that the tab on the back of the bearing is engaged with the slot in the main bearing cap.
Put clean engine oil on the bearing.
Illustration 2 g00588164
Put the Number 5 main bearing cap in position. The cylinder number is on the bottom of the main bearing cap. Ensure that the number is facing toward the front of the cylinder block. Note: Ensure that the main bearing caps are installed in the original positions. Ensure that the numbers that are stamped on the main bearing caps and the numbers that are on the left side of the oil pan are identical.
Raise main bearing cap (4) on the studs. The weight of each main bearing cap is approximately 69 kg (152 lb).
Ensure that dowel (5) engages with the hole in the cylinder block.
Illustration 3 g00588165
Install washers (6) and nuts (7). Tighten the nuts by hand.
Repeat Step 14 through Step 17 for the Number 3 main bearing cap.
Lower the lifting device.
Illustration 4 g00588166
Illustration 5 g00588167Note: Thrust plate (8) and thrust plate (9) should only be installed on the rear main bearing. If necessary, pry the crankshaft in order to install the plates. Be extremely careful not to contact any of the finished surfaces.
Put clean engine oil on the face of rear thrust plate (8). Roll the thrust plate into position in the cylinder block.
Put clean engine oil on the face of rear thrust plate (9). Roll the thrust plate into position in the cylinder block.
Install the remainder of the main bearing caps. Be sure to follow the procedure that was given in Step 14 through Step 17.
Install the brackets for the crankshaft timing pins.
Illustration 6 g00588169
Illustration 7 g00588171
Put clean engine oil on the face of the washer and the threads of the saddle bolts (10).
Install saddle bolts (10) on the right side of the engine. Begin at the front of the engine. Tighten saddle bolts (10) to a torque of 215 40 N m (160 30 lb ft).
Put the reaction sleeves in position over the nuts. Install wrench (11) into one of the holes in the nut.
Raise the tensioners until the tensioners are against the reaction sleeve.
Install the adapter nuts. Tighten the nuts by using a 12 inch ratchet. After the nuts are tight, the nuts should be loosened 1/4 turn.