5005103 JOHNSON *THROTTLE BODY Assy, Port 115HP

Table 1
Required Tools
Tool Part Number Part Description Qty
A 8H-0663 Bearing Puller 1
5F-7345 Puller 1
126-7183 Crossblock 1
126-7177 Puller Leg 2
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.
Illustration 1 g02086073
Typical example
Remove allen head screw (3) from accessory drive housing (2). Remove allen head screws (6) from accessory drive housing (2).
Remove accessory drive housing (2) from the front housing.
If necessary, follow Step 3.a through Step 3.d in order to disassemble the accessory drive.
Remove circlip (8) from accessory drive housing (2).
Place accessory drive housing (2) onto a suitable support. Press the assembly of gear (5) and bearing (7) and bearing (4) out of accessory drive housing (2).
Use Tooling (A) in order to remove bearing (7) and bearing (4) from gear (5).
Remove gasket (1) from accessory drive housing (2). Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
B 7M-7456 Bearing Mount Compound 1-
C 9S-3263 Thread Lock Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 2 g02086222
Typical example
If necessary, follow Step 1.a through Step 1.e in order to assemble the accessory drive.
Inspect the condition of the teeth and the splines of gear (5) for wear and damage. Inspect bearing (7), bearing (4), and circlip (8). Inspect the front housing for wear and damage. Replace any components that are worn or damaged.
Apply a small continuous bead of Tooling (B) to inner Surface (Y) of bearing (4). Place the gear shaft on a suitable support. Press on the inner race of bearing (4) until bearing (4) is against the shoulder of gear (5). Remove any excess compound.
Apply a small continuous bead of Tooling (B) to inner Surface (Z) of bearing (7). Place the inner race of bearing (7) onto a suitable support. Press the shaft of gear (5) into bearing (7) until the shoulder of the gear is against the bearing. Remove any excess compound.
Apply a small continuous bead of Tooling (B) to the outer Surface (X) of bearing (7) and bearing (4). Place accessory drive housing (2) on a suitable support. Press the assembly of the gear into the accessory drive housing. Ensure that bearing (4) is against the front face of the recess in accessory drive housing (2). Remove any excess compound.
Install circlip (8) into the groove in accessory drive housing (2). Ensure that circlip (8) is correctly positioned in the groove.
Install gasket (1) to accessory drive housing (2).
Inspect the bore in the front housing for damage. If necessary, replace the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove" and Disassembly and Assembly, "Housing (Front) - Install" for the correct procedure.
Lightly lubricate bearing (7), bearing (4), and gear (5) with clean engine lubricating oil. Install the assembly of the accessory drive to the front housing. Ensure that the flange on the accessory drive housing is flush with the front housing.
Install new M8 allen head screws (3) to accessory drive housing (2). Tighten the allen head screws to a torque of 22 N m (195 lb in).
Install a new M12 allen head screw (6) to accessory drive housing (2). Tighten allen head screw (6) to a torque of 78 N m (58 lb ft).
Ensure that there is tactile backlash between the idler gear and the accessory drive gear.