| Required Tools | |||
| Tool | Part Number | Part Name | Qty |
| A | 9U-6198 | Crankshaft Turning Tool | 1 |
| B | 230-6284 | Timing Pin (Camshaft) | 1 |
| C | 230-6283 | Timing Pin (Crankshaft) | 1 |
| D | 1P-2320 | Combination Puller | 1 |
| E | 1P-0510 | Driver Group | 1 |
Start By:
- Remove the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley - Remove and Install".
- Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install".
| NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
| NOTICE |
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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. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates. |
- Use Tooling (A) to ensure that the No. 1 cylinder is at the top center compression stroke. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".
Note: Install Tooling (B) through the camshaft gear. Install Tooling (C) into the crankshaft web.
Show/hide tableNOTICE The valve timing and the fuel injection pump timing will be lost if the crankshaft is rotated when the idler gear is removed.
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Illustration 1 g00997729 - Loosen bolt (2). Remove spacer (1) in order to allow bolt (2) to tighten against the shaft of the fuel injection pump. Rotate the fuel injection pump gear in a counterclockwise direction in order to remove the backlash. Tighten bolt (2) to a torque of
31 N·m (23 lb ft) .Note: Bolt (1) must be tightened in order to prevent the shaft of the fuel injection pump from rotating.
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Illustration 2 g00997731 - Remove nut (3) and the washer from the shaft of the fuel injection pump.
- Install Tooling (D) and remove fuel injection pump gear (4).
Note: Do Not pry the fuel injection pump gear from the shaft of the fuel injection pump.
- Remove bolts (7) and retaining plate (6).
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Illustration 3 g00992822 - Remove idler gear (5) and idler gear hub (9).
- Use Tooling (E) and remove bushings (8) from each side of the idler gear.
| A | 9U-6198 | Crankshaft Turning Tool | 1 |
| B | 230-6284 | Timing Pin (Camshaft) | 1 |
| C | 230-6283 | Timing Pin (Crankshaft) | 1 |
| E | 1P-0510 | Driver Group | 1 |
| NOTICE |
|---|
|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Use Tooling (A) to ensure that the No. 1 cylinder is at the top center compression stroke. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".
Note: Install Tooling (B) through the camshaft gear. Install Tooling (C) into the crankshaft web.
Show/hide tableNOTICE The valve timing and the fuel injection pump timing will be lost if the crankshaft is rotated when the idler gear is removed.
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Illustration 4 g00943872 - Position idler gear hub (9) and install bolts (7) in order to locate the idler gear hub. Tighten the bolts in order to seat the idler gear hub.
Note: The Lubrication Hole (X) of the idler gear hub must be positioned at the top of the idler gear hub.
- Use a suitable press and Tooling (E) to install bushings (8) on each side of idler gear (5).
- Remove bolts (7) from the idler gear hub. Install idler gear (5) on idler gear hub (9).
Note: When you install the idler gear, ensure that the marked teeth are facing toward the front.
- Install retainer plate (6) and bolts (7). Tighten the bolts to a torque of
44 N·m (32 lb ft) .Show/hide table
Illustration 5 g00944081 - Check the end play for the idler gear. The end play for the idler gear is
0.10 to 0.20 mm (0.004 to 0.008 inch) .Show/hide table
Illustration 6 g00944084 - Check the backlash between the idler gear and the camshaft gear. The backlash for the gears is
0.052 to 0.107 mm (0.0020 to 0.0042 inch) . - Check the backlash between the idler gear and the crankshaft gear. The backlash for the gears is
0.064 to 0.124 mm (0.0025 to 0.0049 inch) .Show/hide table
Illustration 7 g00992853 Note: Ensure that the mating surfaces of the fuel injection pump gear and the shaft of the fuel injection pump are clean. Lubricate the threads of the shaft for the fuel injection pump. The nut must turn freely until contact is made with the fuel injection pump gear.
- Position fuel injection pump gear (4) on the shaft of the fuel injection pump. Rotate the fuel injection pump gear in a counterclockwise direction in order to remove the backlash. Install the washer and nut (3). Tighten the nut to a torque of
24 N·m (17 lb ft) .Show/hide table
Illustration 8 g00997729 - Loosen bolt (1). Move spacer (2) in order to prevent bolt (1) from tightening against the shaft of the fuel injection pump. Tighten bolt (1) to a torque of
12 N·m (106 lb in) .Note: Spacer (2) must be correctly positioned and bolt (1) must be tightened in order to prevent the bolt from contacting the shaft of the fuel injection pump.
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Illustration 9 g00992883 - Tighten nut (3) to a torque of
88 N·m (65 lb ft) . - Remove Tooling (B) and Tooling (C).
End By:
- Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install".
- Install the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley - Remove and Install".