5031287 JOHNSON PLUG, SPARK (DCPR6E)

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     1P-0520     Driver Gp     1    
B     -     Guide Stud
5/8 - 18 by 12 inch     1    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Apply clean engine oil to the bearings and the shaft assemblies prior to installation on the engine.
Illustration 1 g01151842
Install the O-ring seals and the sealing plates on the cylinder head.
Install adapter assemblies (15), thrust plates (14), and bolts (13) .
Position shaft assembly (17) and install bolts (16) .
Illustration 2 g02087918
Illustration 3 g02087895
(X) Marker (Y) Alignment Mark
Illustration 4 g02088394
Illustration 5 g01151468
Note: Align the timing marks on gear assemblies (4) with the timing marks on the rear housing and align the dowels on gear assemblies (4) with the adapter assemblies.
Position gear assemblies (4) and install bolts (5) .
Install Tooling (B) in the crankshaft. Install gear assembly (12) .
If the top center position is already marked on the vibration damper, proceed to Step 7.
Install the flywheel housing and the flywheel temporarily. Two bolts in the flywheel housing and the flywheel are sufficient.
Position the number one piston in the top center position (TC). The engine should be at the top center position in order to install the rear gear group. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".
With the number one piston in the top center position (TC), attach a marker to the engine and place an Alignment Mark on the vibration damper.
Remove the flywheel and the flywheel housing.
Install two nuts on two bolts for the flywheel (18). The nuts will provide spacing when the bolts are installed. Install two bolts for the flywheel (18) in gear assembly (12) .
Use Tooling (A) and a suitable press to install the bearing in gear assembly (1). Install the bearing to a depth of 2.6 0.5 mm (0.10 0.02 inch).
Install shaft assembly (3), gear assembly (1), and bolts (2). Tighten the bolts (2) to a torque of 55 10 N m (41 7 lb ft).
Use Tooling (A) and a suitable press to install the bearing in gear assembly (6). Install the bearing to a depth of 2.6 0.5 mm (0.10 0.02 inch).
Install shaft assembly (7), gear assembly (6), and bolts (8) .
Use Tooling (A) and a suitable press to install the bearing in gear assembly (9). Install the bearing to a depth of 3.2 0.5 mm (0.13 0.02 inch).Note: Ensure that the number one piston is in the top center position (TC). Ensure that the timing marks on gear assemblies (4) are in alignment with the timing marks on the rear housing.Note: Do not use the alignment marks found on gears (9) and (12). Doing so will create errors. Use the following steps to align gear (9) .
Hold gear assembly (6) in the direction of normal engine rotation in order to remove the backlash. Place gear assembly (9) on the shaft assembly. The teeth on gear assembly (9) will engage with gear assembly (12) first. The teeth on gear assembly (9) will engage with the teeth on gear assembly (6) next. If the teeth on gear assembly (9) do not engage properly, turn the gear assembly to the next tooth and try again.
Install thrust plate (11) and bolts (10) .
Turn the engine in the opposite direction of normal engine rotation for approximately 45 degrees. Turn the engine in the direction of normal engine rotation until the alignment mark on the vibration damper and the marker on the engine are aligned. Ensure that timing marks on gear assemblies (4) are in alignment with the marks on the rear housing.
Tighten the bolts on gear assemblies (4) to a torque of 240 40 N m (177 30 lb ft). Tighten the bolts in the following sequence: 1, 4, 2, 5, 3, 6, 1, 4.End By: Install the flywheel housing.