B5.9G, B5.9LPG – Troubleshooting and Repair Manual – 001-060   Engine Position Sensor Housing

T-25 Torx

Disconnect the four pin weather pack connector.

Remove the engine position sensor.

Remove the engine position sensor housing.

1/2 Inch Drive, 3377371, Engine Barring Gear

Relocating the Engine Position Sensor Housing

The location of the engine position sensor assembly on the gear housing is critical for correct engine adjustments. Follow this procedure to install the assembly so that it corresponds to top dead center (TDC) for cylinder No. 1.

Verify that the No. 1 cylinder is at or near TDC on the compression stroke by rotating the crankshaft until the engine position sensor hole is visible in the cam gear viewed through the gear housing.

10 mm

If the rocker lever pedestal assembly is removed, install the rocker lever pedestal assembly for cylinder No. 1.

Refer to Procedure 003-008-026.

10 mm

Remove the spark plugs from all of the cylinders.

NOTE: This step is important to vent the cylinders so the crankshaft can be rotated smoothly to locate TDC for cylinder No. 1.

18 mm

If removed, temporarily install the crankshaft damper or crankshaft pulley.

Fabricate and install a wire pointer for the front of the engine. This can be done by forming a piece of wire that can be tightened under one of the gear housing capscrews. The wire should extend from the gear housing to a place on the crankshaft vibration damper that is easily seen.

Rotate the crankshaft one-quarter revolution in the direction of normal engine rotation.

Tighten the adjusting screw for the No. 1 intake valve to zero (0) lash plus 5 turns.

CAUTION  Use extreme care when rotating the crankshaft. Use of too much force could damage the valve or push rod.

Rotate the crankshaft slowly in the opposite direction of normal engine rotation until the piston touches the intake valve.

Mark the vibration damper at the wire pointer.

CAUTION  Make sure that the piston touches the intake valve with approximately the same amount of force as in the previous step.

Rotate the crankshaft in the direction of normal engine rotation until the piston touches the intake valve.

Mark the vibration damper at the wire pointer.

Measure the distance and mark the vibration damper at one-half the distance between the two marks. This mark is the TDC mark.

Rotate the crankshaft in the direction of normal engine rotation until the pointer is aligned with the TDC mark, then rotate the crankshaft one additional revolution.

The engine position sensor hole in the cam gear should be visible or felt through the back side of the gear housing. If not, the crankshaft must be rotated one revolution in the direction of engine rotation.

3824936 EPS Housing Locating Tool

Install the engine position sensor locating tool into the sensor housing.

Apply a coat of Loctite™ 59241 to the threads of the torx screws and install the engine position sensor housing.

T-25 Torx

Hold the engine position sensor tool in the camshaft gear hole to align the housing.

Remove the engine position sensor locating tool.

Install the engine position sensor and new o-ring.

Connect the four pin weather pack connector.

If removed, install the remaining rocker lever pedestal assemblies. Refer to Procedure 003-008.

Tighten the rocker lever pedestal mounting capscrews.

Refer to Procedure 003-008.

Complete the installation of the removed components.

• Adjust the valves. Refer to Procedure 003-004.
• Gear cover. Refer to Procedure 001-031.
• Vibration damper. Refer to Procedure 001-051.

Operate the engine at idle for 5 to 10 minutes and check for leaks and loose parts.