Usage:
Start By:
a. remove rocker shaft assemblies and push rods
b. remove governor fastener group
1. Remove access covers (1) from the sides of the engine.
2. Remove bolts (3) and caps (4) that hold fuel rods (2) to the fuel control shaft.
3. Remove bolts (5) to remove lever assembly (6) and fuel rod assembly (2) as a unit from the cylinder heads. If necessary, use tool (A) to turn the flywheel until the camshaft is moved in a position so that the fuel rod assembly can be removed between the engine block and camshaft.
4. Remove the covers over the camshaft drive gears.
5. Remove the bolts and plates (7) that fasten gears (8) to the camshafts.
6. Put the three washers from tooling (B) behind plate (7) and install the bolt and plate (7).
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Do not apply more than 51675 kPa (7500 psi) pressure to 1P0820 Hydraulic Puller. 8B7559 adapters are rated at 6 1/2 ton each and 1P0820 Hydraulic Puller is rated at 17 ton at 68,900 kPa (10000 psi). If too much pressure is applied, the gear may be damaged. Personal injury can also be the result. |
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7. Install tooling (B) on camshaft drive gear (8). Apply 51,675 kPa (7500 psi) to the puller and hit the screw part of the puller with a hammer until the gear is free of the camshaft taper. Remove tooling (B) and gears (8).
8. Remove bolts (9) and thrust washers (10) that fasten the camshafts in the engine block.
9. Push the valve lifters up away from the camshaft into the cylinder head assemblies, and hold the lifters in position. O-ring seals (11) can be used to hold the valve lifters up.
Typical Example
10. Remove the bolts and cover (12) from the front of the engine.
Typical Example
11. Install tooling (C) on each end of camshaft (13).
NOTE: Tool (D) can be installed on the flywheel housing to remove the camshafts from the rear of the engine, or it can be installed on the front drive housing to remove the camshafts from the front of the engine.
12. Install tool (D) on the flywheel housing as shown.
13. Install tool (E) on one end of tooling (C).
14. Pull the camshaft out while rotating it with tool (E). Pull the camshaft out of the engine until a hoist can be fastened to it. Remove camshaft (13) from the engine. The weight of the camshaft and tooling (C) is approximately 56 kg (123 lb) for a 3508, 78 kg (172 lb) for a 3512, and 89 kg (196 lb) for a 3516.
15. Remove bolts (14). Separate the camshafts, and remove spacer (15).
16. If necessary, remove the dowel from the end of the camshaft.
Install Camshaft
Typical Example
1. Put tool (D) in position on the flywheel housing as shown. Install the bolts that hold it. Do not tighten the bolts at this time.
2. Install tool (C) on the end of camshaft (13).
3. Install camshaft (13) in the engine until tool (C) is located in the first cam bearing.
4. Rotate the camshaft, and tighten the bolts that hold tool (D) to the flywheel housing.
5. Rotate the camshaft, and install it until the end of the camshaft is just out of tool (D).
Typical Example
Typical Example
6. If dowel (16) was removed from camshaft (17), install the dowel in the camshaft. Install the dowel until the end of the dowel is 22.0 ± 0.5 mm (.87 ± .02 in) above the surface of the camshaft.
NOTE: Make sure the camshafts are installed respective to the marks (rear L.H., rear R.H.) on the ends of the camshafts.
7. Fasten a hoist to camshaft (17). Put spacer (15) and camshaft (13) in position on camshaft (17). Put 9S3263 Thread Lock on threads of bolts (14). Install bolts (14) to hold the camshafts together. Tighten bolts (14) by hand to a torque of 55 ± 7 N·m (41 ± 5 lb ft).
8. Install tooling (C) and (E) on the end of camshaft (17).
9. Rotate and install the camshaft the remainder of the way.
10. Remove the tooling from the flywheel housing and camshaft.
11. Install washers (10) and bolts (9) to hold the camshafts in place.
12. Remove timing pin (18) from the storage position on the side of the engine.
13. Turn the camshaft until timing pin (18) can be installed through the cylinder block and into groove (19) in the camshaft.
14. Remove cover (20) and plug (21) from the flywheel housing.
NOTE: When rotating the engine with tool (A), it must turn in a counter-clockwise direction, as seen from the flywheel, to remove gear backlash. If the timing hole in the flywheel is missed, turn it clockwise a minimum of 30 degrees before rotating it counter-clockwise.
15. Put Timing bolt (22) in position in the flywheel housing. Use tool (A) and a ratchet to turn the flywheel until the timing pin can be installed in the hole in the flywheel. The No. 1 cylinder is now at top dead center.
16. Put camshaft drive gears (8) in position and install plates (7) and bolts (23).
NOTE: For correct timing, all gear clearance (backlash) must be removed. Turn camshaft drive gears (8) in the same direction as crankshaft rotation and hold them in this position when bolts (23) are tightened.
17. Use the following procedure in order to install the camshaft drive gear:
a. Clean camshaft taper with a lint free cloth saturated with solvent to remove excess oil. Then clean camshaft taper with a lint free alcohol wipe to remove any residue. If the wipe is dirty after cleaning the camshaft taper, clean again with new alcohol wipe until the wipe comes back clean.
NOTE: It is critical that the camshaft taper be very clean, dry and free of residue before assembly.
b. Repeat Step a for the remaining camshaft.
c. Clean camshaft drive gear tapered bore with a lint free cloth saturated with solvent to remove excess oil. Then clean camshaft drive gear tapered bore with a lint free alcohol wipe to remove any residue. If the wipe is dirty after cleaning the camshaft drive gear tapered bore, clean again with new alcohol wipe until the wipe comes back clean.
NOTE: It is critical that the camshaft drive gear tapered bore be very clean, dry and free of residue before assembly.
d. Repeat step c for remaining camshaft drive gear.
e. Check that camshafts are pinned.
f. Check that the flywheel is pinned.
g. Place gears on the camshafts and remove backlash by rotating the gears in the opposite direction of camshaft rotation.
NOTE: For STANDARD ROTATION engines, turn the camshaft gears COUNTERCLOCKWISE. For REVERSE ROTATION engines, turn the camshaft gears CLOCKWISE.
h. Install Timing Ring, accessory drive gear or plate if applicable.
NOTE: Ensure that the hole in the timing ring is properly seated on the locating pin.
i. Torque cam gear retaining bolts to 360 N·m (265 lb ft).
j. Mark a vertical line on the cam gear retaining bolt head.
k. Place driver against cam gear retaining plate and ring solidly with hammer 3-4 times.
l. Retorque the cam gear retaining bolt to 360 N·m (265 ft lb).
m. Repeat steps k and l until the mark on the bolt has turned a minimum of 1/4 turn.
n. Cam gear installation is complete.
18. Install the gaskets and covers over the camshaft drive gears. Be sure the long bolts are installed through the holes in the cover with the dowels.
19. Remove the timing pins from the camshafts, and install them in their storage positions.
20. Remove the timing bolts from the flywheel, and install the plug in the timing hole. Remove tool (A) and install the cover on the flywheel housing.
21. Install the gasket and cover (12) on the left side of the front drive housing.
22. Remove O-ring seals (11) from the valve lifters. Push the valve lifters down against the camshaft.
23. Install fuel rod assembly (2) and lever assembly (6), as a unit, in the cylinder head assemblies. If necessary, use tool (A) to turn the camshafts until the fuel rod assembly can be installed.
24. Make sure lever assembly (6) is engaged correctly with the fuel injection pump rack, and install the bolts.
25. Install the bolt and cap (4) to hold the fuel rod assembly to the fuel control shaft.
26. Install access covers (1) on each side of the engine.
End By:
a. install governor fastener group
b. install rocker shaft assemblies and pushrods