C7.1 Marine Propulsion Engine Caterpillar

Gear Group (Front) - Remove and Install

Usage:

C7.1 GJN

Removal procedure

Reference: Special Instruction, "Visual Service Procedures - Colors and Symbols" M0066576.

Show/hide table

Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A⁽¹⁾	9U-6198	Crankshaft Turning Tool	1
A⁽²⁾	9U-7336	Housing	1
A⁽²⁾	5P-7305	Engine Turning Tool	1
B	136-4632	Timing Pin (Crankshaft)	1
B	268-1966	Adapter	1
C	364-9107	Fuel Injection Pump Timing Pin	1
D	230-6284	Timing Pin (Camshaft)	1
E	298-5564	T40 Torx Socket	1

Show/hide table

⁽¹⁾	The Crankshaft Turning Tool is used on the front pulley.
⁽²⁾	This Tool is used in the aperture for the electric starting motor.

Start By:

Remove the front cover.
Remove the valve mechanism cover.

Show/hide table

NOTICE

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.

Show/hide table

NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Note: Either Tooling (A) can be used. Use the Tooling that is most suitable. Care must be taken to ensure that the fuel injection pump timing is not lost during the removal of the front gear group. Carefully follow the procedure to remove the gear group.

Show/hide table




Illustration 1	g06270101
Use Tooling (A) to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.

Show/hide table




Illustration 2	g06270102
Install the tooling to lock the crankshaft.

Show/hide table




Illustration 3	g06270103
Use Tooling (A) to rotate the crankshaft in a clockwise direction and position the crankshaft at 60 degrees after top dead center.

Show/hide table




Illustration 4	g06270104

Note: Ensure that all threaded inserts are fully unscrewed.

Use Tooling (A) to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.

Show/hide table




Illustration 5	g06270105

Show/hide table




Illustration 6	g06270108

Note: Do not use excessive force to install the Tooling . Do not use the Tooling to hold the crankshaft during repairs.

Show/hide table




Illustration 7	g06270110

Show/hide table




Illustration 8	g06270111
Mark the gears to show alignment.

Note: Identification will ensure that the gears can be installed in the original alignment.

Show/hide table




Illustration 9	g06270123

Show/hide table




Illustration 10	g06270124

Show/hide table




Illustration 11	g06270126

Show/hide table




Illustration 12	g06270128
Remove the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install" for the correct procedure. Remove the idler gear. Refer to Disassembly and Assembly, "Idler Gear - Remove and Install" for the correct procedure.

Installation Procedure

Show/hide table

Table 2
Required Tools
Tool	Part Number	Part Description	Qty
B	136-4632	Timing Pin (Crankshaft)	1
B	268-1966	Adapter	1
C	364-9107	Fuel Injection Pump Timing Pin	1
D	230-6284	Timing Pin (Camshaft)	1
E	298-5564	T40 Torx Socket	1
F	7H-1942	Dial Indicator	1
F	-	Magnetic Base and Stand	1

Show/hide table

NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Note: The fuel injection pump must remain locked until the procedure instructs you to unlock the fuel injection pump.

Ensure that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center for No. 1 Piston" for the correct procedure.

Show/hide table




Illustration 13	g06270129
If necessary, install the tooling.

Note: Do not use excessive force to install the tooling. Do not use the tooling to hold the crankshaft during repairs.

Show/hide table




Illustration 14	g06270130

Show/hide table




Illustration 15	g06270134
Install the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install" for the correct procedure.

Show/hide table




Illustration 16	g06270136

Show/hide table




Illustration 17	g06270137
Install the idler gear. Refer to Disassembly and Assembly, "Idler Gear - Remove and Install". Check the end play of the idler gear. Refer to Specifications, "Gear Group (Front)".

Show/hide table




Illustration 18	g06270138

Show/hide table




Illustration 19	g06270139

Show/hide table




Illustration 20	g06270143
Check the end play of the camshaft gear. Refer to Specifications, "Camshaft" for more information.

Show/hide table




Illustration 21	g06270144
Use Tooling (F) to measure the backlash for the gears. Refer to Specifications, "Gear Group (Front)" for more information. Lubricate each gear with clean lubricating engine oil. If necessary, use Tooling (A) to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure. If necessary, use Tooling (B) to lock the crankshaft so that number one piston is at top dead center on the compression stroke.

Show/hide table




Illustration 22	g06270145

Show/hide table

NOTICE

Failure to ensure that the crankshaft is positioned at 60 degrees after top dead center will result in interference between the pistons and the valves. Interference between the pistons and the valves will result in damage to the engine.

Use Tooling (A) to rotate the crankshaft in a clockwise direction and position the crankshaft at 60 degrees after top dead center.

Show/hide table




Illustration 23	g06270146

Note: When the threaded insert is tightened, the threaded insert must be seated correctly into the cup for the pushrod.

Show/hide table




Illustration 24	g06270149
The engine should not be operated for a period 30 minutes after the threaded inserts on all the rocker arms have been tightened. This period will allow the force from the valve springs to purge off excessive engine oil from the hydraulic lifters.