Required Tools | |||
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Tool | Part Number | Part Description | Qty |
A | 1P-0510 | Driver | 1 |
B | 8T-2998 | Lubricant | - |
185-4758(1) | Lubricant | - | |
C | - | Loctite 587 | - |
D | - | Loctite 242 | - |
(1) | For use in EAME |
Start By:
- Remove the front housing.
- Remove the air compressor, if necessary.
- Remove the water pump, if necessary.
- Remove the auxiliary water pump, if necessary.
- Remove the fuel transfer pump, if necessary.
NOTICE |
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Do not turn the crankshaft or the camshaft while the camshaft gear is removed. If the front gear group is not correctly timed during installation, interference can occur between the pistons and the valves, resulting in damage to the engine. |
Note: Be sure to mark the orientation of each of the gears for installation purposes.
- Remove bolts (2) and thrust plate (1).
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Illustration 2 g01008430 - Remove sealing plate (3) and adapter (4).
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Illustration 3 g01008431 - Remove O-ring seal (5) and O-ring seal (6) from sealing plate (3).
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Illustration 4 g01101536 - Remove bolts (8), plate (9), and adjustable idler gear assembly (7).
- Use Tooling (A) and remove the sleeve bearing from adjustable idler gear assembly (7).
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Illustration 5 g01101045 - Remove bolts (11), plate (12), and idler gear assembly (10).
- Use Tooling (A) and remove the sleeve bearing from idler gear assembly (10).
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Illustration 6 g01101048 - Remove bolts (14), plate (15), and cluster gear assembly (13).
- Use Tooling (A) and remove the sleeve bearing from cluster gear assembly (13).
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Illustration 7 g01101050 Note: Stub shaft assembly (16) must be removed in order to remove plate (22). The backlash for the camshaft gear and the adjustable idler gear assembly will need to be readjusted at assembly.
- Remove nuts (17) and remove stub shaft assembly (16).
Note: Stub shaft (18) must be removed in order to remove plate (22).
- Remove nuts (19) and remove stub shaft (18).
- Remove bolts (21) and remove stub shaft (20).
- Remove locking bolts (23) that hold plate (22) to the cylinder block. Remove plate (22).
- If studs (24) are loose or the threads are damaged, remove the studs from the front plate.
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Illustration 8 g01101052 - Remove integral seal (25) from the cylinder block.
Illustration 1 | g01008429 |
NOTICE |
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Do not turn the crankshaft or the camshaft while the camshaft gear is removed. If the front gear group is not correctly timed during installation, interference can occur between the pistons and the valves, resulting in damage to the engine. |
- Thoroughly clean the gasket material from the cylinder block and both sides of the plate.
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Illustration 9 g01101567 - If studs (24) are loose or the threads are damaged, install new studs (24) in the front plate. Apply Tooling (D) to the serrations of studs (24). Install studs (24) in the front plate.
- Install integral seal (25) on the dowel pins on the cylinder block.
Note: Apply Tooling (C) to the bottom of integral seal (25) to fill the space at the cylinder block, front housing, and engine oil pan.
- Install plate (22) on the dowel pins on the cylinder block. Install new locking bolts (23) (Marked "X") in order to fasten the front plate to the cylinder block. Tighten locking bolts (23) to a torque of
55 N·m (41 lb ft) .Note: Clean the old sealant from the bolts and apply Tooling (D) to the bolts.
- Tighten locking bolts (23) again to a torque of
55 N·m (41 lb ft) .Show/hide tableIllustration 10 g01101565 - Install stub shaft (18). Apply Tooling (D) to the studs and the bolt for stub shaft (18). Tighten nuts (19) and the bolt to a torque of
55 ± 10 N·m (41 ± 7 lb ft) . - Install stub shaft assembly (16). Apply Tooling (D) to the studs and the bolt for stub shaft assembly (16). Do not tighten nuts (17) and the bolt for stub shaft assembly (16) at this time. Nuts (17) and the bolt for stub shaft assembly (16) will need to be tightened when the backlash is adjusted.
- Adjust the backlash between the camshaft gear and the adjustable idler gear assembly. The backlash should be
0.356 ± 0.254 mm (0.014 ± 0.010 inch) . Refer to Testing and Adjusting, "Gear Group (Front) - Time" for the backlash adjustment procedure. Tighten nuts (17) and the bolt to a torque of55 ± 10 N·m (41 ± 7 lb ft) . - Install stub shaft (20). Apply Tooling (D) to bolts (21). Install bolts (21) and tighten in a numeric sequence 1, 3, 4, 5, 2, 1, 2, 3, 4, 5, 1 to a torque of
55 ± 10 N·m (41 ± 7 lb ft) .Show/hide tableIllustration 11 g01101161 - Use Tooling (A) to install the sleeve bearing in cluster gear assembly (13).
- Put cluster gear assembly (13) on the stub shaft. Ensure that Timing Marks (V) are aligned on the cluster gear assembly and the crankshaft gear.
- Position plate (15) with the oil groove toward the face of the gear. Apply Tooling (D) to bolts (14). Install bolts (14). Tighten bolts (14) to a torque of
30 ± 7 N·m (22 ± 5 lb ft) .Show/hide tableIllustration 12 g01101045 - Use Tooling (A) to install the sleeve in idler gear assembly (10).
- Put idler gear assembly (10) on the stub shaft. Install plate (12) with the oil groove toward the gear face. Apply Tooling (D) to bolts (11). Install bolts (11). Tighten bolts (11) to a torque of
30 ± 7 N·m (22 ± 5 lb ft) .Show/hide tableIllustration 13 g01008436 - Use Tooling (A) to install the sleeve bearing in adjustable idler gear assembly (7).
Note: Align the oil hole in the bearing with the oil hole in the adjustable idler gear assembly.
- Put adjustable idler gear assembly (7) on the stub shaft assembly. Position plate (9) with the oil groove toward the face of the gear. Apply Tooling (D) to bolts (8). Install bolts (8). Tighten bolts (8) to a torque of
30 ± 7 N·m (22 ± 5 lb ft) .Note: Check the backlash for the camshaft gear and the adjustable idler gear assembly. The camshaft gear must be installed and the adjustable idler gear assembly must be removed in order to perform the backlash adjustment procedure. Refer to Testing and Adjusting, "Gear Group (Front) - Time".
Show/hide tableIllustration 14 g01008431 - Install O-ring seal (5) and O-ring seal (6) in sealing plate (3). Lubricate O-ring seal (6) with a 50/50 mixture of Tooling (B) and clean engine oil.
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Illustration 15 g01008430 Show/hide tableIllustration 16 g01010256 - Install adapter (4). Ensure that the dowel in the adapter engages the hole in the camshaft.
- Install sealing plate (3) and thrust plate (1). Ensure that the dowel in the adapter engages the hole in the thrust plate. Apply Tooling (D) to bolts (2). Install bolts (2). Evenly tighten bolts (2) in order to ensure that sealing plate (3) and O-ring seal (5) are seated against the cylinder head.
- Adjust the backlash for the camshaft gear and the adjustable idler gear, if necessary. Refer to Testing and Adjusting, "Gear Group (Front) - Time".
Note: The camshaft gear must be installed and the adjustable idler gear must be removed in order to perform the backlash adjustment procedure.
End By:
- Install the fuel transfer pump, if necessary.
- Install the auxiliary water pump, if necessary.
- Install the water pump, if necessary.
- Install the air compressor, if necessary.
- Install the front housing.