Usage:
Start By:
a. remove timing gear cover
b. remove electric starting motor
1. Time the engine as follows:
a. Install Tool (A) in the flywheel housing
b. Remove the cover from the side of the fuel injection pump housing so Tool (B) can be installed. Remove the plug from the flywheel housing so bolt (1) can be installed.
NOTE: The engine is seen from the flywheel end when the direction of rotation is given.
c. Turn the flywheel counterclockwise until Tool (B) can be installed in the fuel injection pump housing and located in the groove in the fuel injection pump camshaft, a 3/8 in-16 NC × 2.25 in long bolt (1) can be installed in the flywheel through the hole in the flywheel housing, and the "C" marks on the crankshaft gear and the camshaft gear are in alignment with each other.
2. Loosen bolt (2) until there is approximately 3.18 mm (.125 in) gap between washer (3) and fuel pump drive gear (4).
3. Install Tooling (C) as shown, and loosen the fuel pump drive gear from the taper on the fuel injection pump camshaft. Remove Tooling (C), the bolt, washer and fuel pump drive gear.
4. Remove the bolts and plate (5) that hold idler gear (6) in position. Remove the idler gear. If necessary, remove the bearing from the idler gear with Tooling (D) and a press.
| NOTICE |
|---|
Do not turn the crankshaft after camshaft gear (7) has been removed. Turning the crankshaft will cause damage to the valves. |
5. Remove the four bolts that hold camshaft gear (7) to the camshaft. Remove the camshaft gear.
6. Remove the three nuts on the back side of timing gear plate (8) that hold the fuel pump housing to timing gear plate (8).
7. Bend locks (9) away from the bolts.
8. Remove the bolts, locks (9), and timing gear plate (8) from the cylinder block.
9. Remove the old gasket material from the cylinder block and timing gear plate (8).
Install Timing Gears & Plate
1. Make sure O-ring seal (10) is in place on the fuel pump housing.
2. Install a new gasket on the cylinder block. Cut the gasket even with the bottom face of the cylinder block. Put 5H-2471 Gasket Cement on the bottom of the gasket where the gasket makes contact with the gasket for the oil pan.
3. Put timing gear plate (8) in position on the cylinder block. Install the three nuts that hold the fuel pump housing onto the back side of timing gear plate (8). Install locks (9) and the six bolts that hold timing gear plate (8) in place. Bend locks (9) against the bolts.
4. Install camshaft gear (7) with the "C" mark on the camshaft gear in alignment with the "C" mark on the crankshaft gear. Install the washers and bolts (11) that hold camshaft gear (7) to the camshaft.
5. Install the bearing in idler gear (6) with Tooling (D) and a press. The end of the bearing must be 1.52 mm (.060 in) below the face of the gear hub.
6. Be sure the oil hole in the shaft for idler gear (6) is open. Put idler gear (6) in position. Install plate (5) and bolts (12).
7. Make sure Tooling (B) is in position in the groove of the fuel injection pump camshaft.
8. Put fuel injection pump drive gear (4) in position on the fuel injection pump camshaft. Put washer (3) in position on the gear with the largest diameter toward the front of the engine. Install bolt (2), and tighten it to a torque of 7 N·m (5 lb ft).
NOTE: Make sure bolt (2) does not turn while the flywheel is being turned.
NOTE: The engine is seen from the flywheel end when the direction of rotation is given.
9. Remove bolt (1) from the flywheel. Use Tool (A) to turn the flywheel clockwise until the "C" mark on the crankshaft gear moves 30 degrees.
10. Turn the flywheel counterclockwise until the 3/8 in-16 NC × 57.1 mm (2.25 in) bolt (1) can be installed in the flywheel and the "C" marks are in alignment. This will remove all the backlash from the timing gears.
11. Install a 3/81/2 in-24 NF × 12.7 mm ( in) long bolt in one of the holes in fuel injection pump drive gear (4).
12. Put a torque wrench on the 3/8 in bolt with the wrench in line with the center of the drive gear, and give it a torque of 60 to 70 N·m (45 to 50 lb ft). While this torque is held, tighten the drive gear bolt to a torque of 270 ± 25 N·m (200 ± 18 lb ft).
13. Remove Tool (B) from the fuel injection pump housing and install the cover.
14. Remove bolt (1) from the flywheel and install the plug in the flywheel housing.
15. Remove Tool (A) from the flywheel housing.
End By:
a. install timing gear cover
b. install electric starting motor