Usage:
preparatory steps:
a) remove flywheel housing
b) remove valve covers
1. Rotate the crankshaft counterclockwise (as viewed from rear of engine) to top dead center compression stroke No.1 piston. See LOCATING TOP DEAD CENTER COMPRESSION POSITION FOR NO.1 PISTON in TESTING AND ADJUSTING. Install the camshaft timing pins in the right and left inlet camshaft.
2. Remove the fuel injection pump camshaft timing pin from its storage hole. Install the timing pin in timing hole in fuel injection pump camshaft.
3. Remove the oil pump drive idler gear (1), retaining bolts, lock, and washer from flywheel housing. Using tool setup (A), remove bearing from idler gear. Remove the timing gear thrust washers from flywheel housing. Remove the water pump drive gear and idler gear bearings (2) from the flywheel housing.
4. Remove the water pump drive idler gear (3).
5. Remove the rear balancer (4) and thrust washer. Using tool setup (B), remove the bearing from balancer.
6. Remove the idler gear (5) and thrust washer. Using tool setup (C), remove bearing from idler gear.
7. Remove the variable timing unit cover (6). Remove the timing gear plate retaining bolts and locks. Remove the plate (7) - weight 40 lbs. (18 kg). Remove water pump drive idler gear thrust washer and bearing.
8. Remove oil line (8). Remove the camshaft drive idler gear (9), retaining bolts, lock, and shaft. Using tool setup (D), remove bearing from gear.
Install Rear Timing Gears And Plate
1. Using tool setup (D), install bearing in camshaft drive idler gear. Install gear, retaining bolts, lock, and shaft. Install oil line.
2. Install water pump drive idler gear bearing in plate using tool setup (E). Install thrust washer. Install new timing gear plate-to-cylinder block gasket. Position the timing gear plate on engine, and install retaining bolts and locks. Trim the gasket flush with oil pan face of cylinder block. Install variable timing unit cover.
3. Using tool setup (C), install bearing in idler gear. Install thrust washer in cylinder block. Install idler gear on engine with V-mark on gear aligned with V-mark on crankshaft gear, and R-mark on idler gear toward balancer.
4. Using tool setup (B), install bearing in balancer. Install thrust washer in cylinder block. Install the balancer on engine with R-mark on balancer gear aligned with R-mark on idler gear.
| NOTICE |
|---|
Always be sure that the No.1 piston is at top dead center compression stroke, and the timing pins are installed in timing slots in left and right inlet camshafts and the fuel injection pump camshaft before installing the balancer or idler gear. Damage to the engine can result if above procedure is not followed. |
5. Install the water pump drive idler gear.
6. Install the water pump drive idler gear and idler gear bearings in flywheel housing using tool setup (E). Install the timing gear thrust washers on flywheel housing. Using tool setup (A), install bearing in oil pump drive idler gear. Install oil pump drive idler gear, retaining bolts, lock, and washer on flywheel housing.
7. Remove all timing pins from their timing slots. Install timing pins in their respective storage positions.
concluding steps:
a) install flywheel housing
b) check fuel injection pump camshaft timing as outlined in TESTING AND ADJUSTING
c) install valve covers