Start By:
- Remove the front cover if the front cover has not previously been removed. Refer to this Disassembly and Assembly Manual, "Front Cover - Remove and Install".
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
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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. Dispose of all fluids according to local regulations and mandates. |
Note: There are two types of idler gear that may be installed on these engines. The standard idler gear is supported on the hub by two bushes. The heavy-duty idler gear is supported on the hub by two sets of roller bearings.
- Ensure that the No. 1 cylinder is at top dead center on the compression stroke. Refer to the Testing and Adjusting Manual, "Finding Top Center Position for No. 1 Piston".
Note: Timing pins are used in order to time the engine at top dead center. The timing pins are a slip fit. Do not use excessive force to install the timing pins. Do not use the timing pins to lock the engine during repairs.
- Remove the rocker shaft if the rocker shaft was not previously removed. Refer to this Disassembly and Assembly Manual, "Rocker Shaft and Pushrod - Remove".
- Remove the fuel injection pump gear if the gear has not previously been removed. Refer to this Disassembly and Assembly Manual, "Fuel Injection Pump - Remove".
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Illustration 1 g01149878 Typical example - Remove the three setscrews (3) from the idler gear (2). Remove the plate (4) from the idler gear (2).
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Illustration 2 g01149981 Typical example - Remove the idler gear assembly (2) from the recess in the cylinder block. The assembly (2) must be lifted over the housing for the crankshaft front seal (7) as the assembly is moved forward.
Note: If necessary, remove the glow plugs in order to allow the crankshaft to rotate more freely. Refer to this Disassembly and Assembly Manual, "Glow Plugs - Remove and Install".
Note: In order to remove the heavy-duty idler gear, follow the steps (1 to 4) in the procedure to remove standard idler gear.
- Remove the three setscrews (1). Remove the idler gear assembly from the engine. The plate (3) is removed with this assembly.
- The idler gear assembly must be lifted over the front oil seal housing.
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| Illustration 3 | g01141660 |
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Typical example | |
Note: Do not remove the allen head screw (2) in order to remove the heavy-duty idler gear.