5032044 JOHNSON SWITCH, STARTING MOTOR

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 230-6284 Timing Pin (Camshaft) 1
C 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.Start By:
If the engine is equipped with an air compressor, remove the air compressor. Refer to Disassembly and Assembly, "Air Compressor - Remove and Install".
If the engine is equipped with a vacuum pump, remove the vacuum pump. Refer to Disassembly and Assembly, "Vacuum Pump - Remove and Install".
If the engine is equipped with an accessory drive, remove the accessory drive. Refer to Disassembly and Assembly, "Accessory Drive - Remove and Install".
Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install".
Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install". Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Note: Care must be taken in order to ensure that the fuel injection pump timing is not lost during the removal of the front gear group. Carefully follow the procedure in order to remove the gear group.
Use Tooling (A) in order to rotate the crankshaft so that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Finding Top Centre Position for No.1 Piston".
Illustration 1 g03662683
Typical example
Install Tooling (B) through hole (X) in camshaft gear (1) into the front housing. Use Tooling (B) in order to lock the camshaft in the correct position. Install Tooling (C) into hole (Y) in the front housing. Use Tooling (C) in order to lock the crankshaft in the correct position. Refer to Systems Operation, Testing and Adjusting, "Finding Top Centre Position for No.1 Piston". Note: Do not use excessive force to install Tooling (C). Do not use Tooling (C) to hold the crankshaft during repairs.
Illustration 2 g01322693
Typical example
Loosen nuts (6) on all rocker arms (7). Unscrew adjusters (5) on all rocker arms (7) until all valves are fully closed. Note: Failure to ensure that ALL adjusters are fully unscrewed can result in contact between the valves and pistons.
Illustration 3 g03662706
Typical example
Mark gears (1), (2) and (3) in order to show alignment. Refer to Illustration 3. Note: Identification will ensure that the gears can be installed in the original alignment.
Remove fuel pump gear (3). Refer to Disassembly and Assembly, "Fuel Pump Gear - Remove" for the correct procedure.
Remove camshaft gear (1). Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install".
Remove idler gear (2). Refer to Disassembly and Assembly, "Idler Gear - Remove and Install". Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
B 230-6284 Timing Pin (Camshaft) 1
C 230-6283 Timing Pin (Crankshaft) 1
D 9U-7324 Indicator Bracket 1
7H-1942 Dial Indicator 1
3S-3268 Indicator Contact Point 1
7H-1940 Universal Attachment 1
Keep all parts clean from contaminants.Contaminant