Front Gear Assembly Configuration - JustAnswer · Front Gear Assembly Configuration This procedure...

Front Gear Assembly Configuration

This procedure describes the removal,inspection, and installation of the gear train.

The illustration shown is from left to right andtop to bottom.

Valve camshaft gearCamshaft idler gear (adjustable)Upper idler gearLower idler scissor gearAccessory drive gearFuel pump idler gearFuel pump gear.

Scissor Gear Definitions

Engine Base Timing https://quickserve.cummins.com/qs3/pubsys2/xml/en/procedures/173/17...

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Do not attempt to remove any gears beforereading scissor gear definitions. Seriouspersonal injury or engine damage can resultif instructions are not followed.

The following terms describe the conditions ofthe scissor gears for removal, installation, andoperation.

Unloaded

The gear will be unloaded whenremoving, installing, and setting gearbacklash.Unload the gear by backing out two gearadjusting screws until the gear teeth align.The idler scissor gear is loaded after thegear backlash is set.

Loaded

The gear teeth are loaded (functional) andare spread between the mating gearteeth.The gear is loaded by tightening all of theadjusting screws.

Torque Value: 29 n.m [21 ft-lb]

The gear teeth will be spread and nomovement will be felt against thecrankshaft gear. The gear will be in theloaded condition for engine operation.


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The timing pin and wedge must be installedbefore any gears are removed and mustremain in place until all gears are fullyinstalled and tightened. Failure to install thetiming pin and wedge can lead to impropertiming of the engine, resulting in severeengine damage or engine failure.

Rotate the crankshaft clockwise until the”insert pin” mark on the outside diameter of theengine vibration damper is aligned with themark on the gear housing. Refer to Procedure000-017 in Section 0.

Remove the plug from the timing pin boss.

Insert the crankshaft locking pin, Part Number3163020, into the timing pin boss hole.

The green band on the timing pin will be linedup with the surface of the timing pin boss of theblock.

The pin is not correctly seated in the cranknotch if the green band is either completelyvisible outside the block or is not visible at all.

The crankshaft will be locked in place when thepin is properly seated.


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Remove the exhaust gas recirculation(EGR) crossover tube. Refer to Procedure011-070 in Section 11.Remove the rocker lever cover andgasket. Refer to Procedure 003-011 inSection 3.

The timing code is located on the enginedataplate.

Do not drive the wedge into place. Enginedamage can occur.

Insert the correct timing wedge to lock the valvecamshaft. Lightly tap the top of the timingwedge with a mallet to be sure it is properlyseated.

Make sure the wedge with the proper angle isused and that the wedge is properly seated inits installed position.


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Remove the camshaft position sensor.Refer to Procedure 019-363 in Section 19.Remove the upper gear cover. Refer toProcedure 001-079 in Section 1.Remove the crankshaft position sensor.Refer to Procedure 019-365 in Section 19.Remove the lower gear cover, if needed.Refer to Procedure 001-080 in Section 1.

Valve Camshaft Gear

The lower idler scissor gear must be unloadedduring removal of the valve camshaft gear. Tounload the gear, two of the gear adjustingscrews must be backed out far enough to allowthe teeth on the scissor gear to be aligned.

Unload the lower idler scissor gear.

Remove the valve camshaft gear mountingcapscrew and the camshaft tone wheel.

NOTE: Do not disassemble the camshafttone wheel.


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Install the gear puller, Part Number 3163069.

Install the valve camshaft gear mountingcapscrew completely.

Loosen the capscrew two turns.

Use the gear puller to remove the valvecamshaft gear from the camshaft nose.

Remove the puller.

Do not completely remove the camshaft gearmounting capscrew when the three-jaw puller isused. The capscrew serves as a safety catchby preventing the gear from slipping off of thecamshaft's tapered nose.

Remove the valve camshaft gear mountingcapscrew, spacer, and valve camshaft gear.

Camshaft Idler Gear (Adjustable)

The lower idler scissor gear must be unloadedduring removal of any gears. To unload thegear, two of the gear adjusting screws must bebacked out far enough to allow the teeth on thescissor gear to be aligned.



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The camshaft idler gear shaft can fall out andbe damaged when the camshaft idler gear isremoved.

Remove the retainer capscrews, retainer,camshaft idler gear, and idler gear shaft.

Upper Idler Gear



Remove the retainer capscrews, retainer, upperidler gear, and spacer/shaft assembly.

Accessory Drive Gear

If equipped, remove the air compressor. Referto Procedure 012-014 in Section 12.

Fuel Pump Idler Gear


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Remove the retaining capscrews, shaft, fuelpump idler gear, and thrust bearing.

Lower Idler Scissor Gear



Remove the idler scissor gear capscrews.

Remove the retainer, lower idler scissor gear,shaft, and thrust bearing.

Inspect the gear teeth on all gears for pitting,heavy wear, or breakage.

Replace the suspect gear and inspect themating gear for resulting damage.


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Inspect the idler shafts for heavy wear.

Measure the idler shafts outside diameters.

Lower Idler Shaft Outside Diameter

mm in88.880 MIN 3.499288.894 MAX 3.4998

Upper Idler Shaft Outside Diameter

mm in

88.880 MIN 3.499288.894 MAX 3.4998

Camshaft Idler Gear Shaft Outside Diameter

mm in95.343 MIN 3.753795.357 MAX 3.7542

Fuel Pump Idler Shaft Outside Diameter

mm in78.344 MIN 3.084478.358 MAX 3.0850

Inspect the idler gear bores for heavy wear orpitting.

Measure the inside diameter of the lower idlergear, adjustable idler gear, camshaft idler gear,and fuel pump idler gear bores.

Lower Idler Gear Bore Inside Diameter

mm in88.963 MIN 3.502588.989 MAX 3.5035


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Adjustable Idler Gear Bore Inside Diameter

mm in88.963 MIN 3.502588.989 MAX 3.5035

Camshaft Idler Gear Bore Inside Diameter

mm in95.426 MIN 3.756995.452 MAX 3.7580

Fuel Pump Idler Gear Bore Inside Diameter

mm in

78.426 MIN 3.087678.452 MAX 3.0887

Inspect the thrust bearing(s) for pitting,cracking, scratching, uneven wear, or otherdamage. Replace the thrust bearing(s) andinspect the corresponding gear if damage isfound.

The timing pin and wedge must be installedbefore any gears are removed and mustremain in place until all gears are fullyinstalled and torqued. Failure to install thetiming pin and wedge can lead to impropertiming of the engine, resulting in severeengine damage or engine failure.


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The gear train must be assembled in thesame sequence as this procedure lists.Failure to follow this sequence may result insevere engine damage.

Fuel Pump Idler Gear

Be sure the fuel pump is timed correctly beforeinstalling the fuel pump idler gear. Refer toProcedure 005-037 in Section 5.

Apply Lubriplate™ to the thrust bearing, shaft,and fuel pump idler gear.

Install the thrust bearing, shaft, and fuel pumpidler gear. The shaft must be installed with thealignment mark (1) (stamped on the gearretainer) pointed toward the center of the loweridler scissor gear.

Install the capscrews.

Tighten all capscrews evenly.

Torque Value:

30 n.m [22 ft-lb]1. Rotate each capscrew an additional 60degrees in the same sequence asabove.

2.

Lower Idler Scissor Gear


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The lower scissor idler gear must be unloadedduring installation. To unload the gear, two ofthe gear adjusting screws must be backed outfar enough to allow the teeth on the scissorgear to be aligned.

Apply Lubriplate™ to the thrust bearing, shaft,and lower scissor idler gear.

Install the thrust bearing, shaft, and lowerscissor idler gear. The shaft must be installedwith the word “TOP” (stamped on the end of theshaft) toward the top of the engine.

The slots in the gear retainer plate go towardthe scissor gear.

Install the retainer and capscrews.

Tighten all capscrews in the alternating patternshown in the illustration.

Torque Value:

30 n.m [22 ft-lb]1. Rotate each capscrew an additional 60degrees in the same alternatingpatterns.

2.

NOTE: The lower idler scissor gear mustnot be loaded until all other gears areinstalled and tightened.

Accessory Drive Gear


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If equipped, install the air compressor. Refer toProcedure 012-014 in Section 12.

Upper Idler Gear

Apply Lubriplate™ to the spacer plate/shaftassembly and the upper idler gear.

The spacer plate/shaft assembly is doweled tothe block with two standard dowels.

Install the mounting spacer plate/shaftassembly and the upper idler gear.

The spacer plate/shaft assembly must beinstalled with the word “OIL PAN” (stamped onthe front face of the shaft) oriented toward theoil pan.


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The slots in the gear retainer plate go towardthe upper idler gear

Install the retainer and capscrews.

Tighten all capscrews in the alternating patternas shown in the illustration.

Torque Value:

30 n.m [22 ft-lb]1. Rotate each capscrew an additional 60degrees in the same alternating pattern.

2.

Camshaft Idler Gear (Adjustable)

The camshaft idler gear retainer and shaftmust be oriented with the part number facingoutward, such that the oil drain from thehead is not blocked. If blocked, engineoperation will be affected.

Apply Lubriplate™ to the shaft and camshaftidler gear.

Install the shaft and the adjustable camshaftidler gear. The shaft must be installed with thewords “OIL PAN” (1) and the arrow (stamped onthe front face of the shaft) pointing toward theoil pan.


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The slots in the gear retainer plate go towardthe gear.

Install the retainer and capscrews. Hand-tightenthe capscrews and then loosen by one “flat,”which is 60 degrees.

Be sure that the oil hole in the retainer plateand shaft (1) is in line with the oil drilling in thehead.

NOTE: The camshaft idler gear is installedloosely, because it is moved into its finalposition later in the timing process.

Valve Camshaft Gear

When using solvents, acids, or alkalinematerials for cleaning, follow themanufacturer’s recommendations for use.Wear goggles and protective clothing toreduce the possibility of personal injury.

The valve camshaft nose and valve camshaftgear must be clean and dry prior toassembly. Wipe off the shaft surface andgear with a lint-free cloth and do not touchthe surfaces after wiping. Engine damagecan occur.

The camshaft gear retaining capscrewtorque process must be completed within


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fifteen (15) minutes of Loctite™ applicationor severe engine damage may occur.

Scrape off any Loctite™ residue from the boreof the valve camshaft gear.

Clean the valve camshaft and camshaft gearbore with Envirosol™ 655 solvent, orequivalent, and a lint-free cloth.

Do not spray solvent directly onto the camshaftnose. Spray solvent onto a clean, lint-freecloth, and then wipe the camshaft nose clean.No oil residue can remain and these surfacesare not to be touched once cleaned.

Apply a thin coat of Loctite™ 609, Part Number3823718, to the camshaft nose and camshaftgear bore.

Install the valve camshaft gear loosely on thecamshaft nose taper.

The valve camshaft gear needs to be fullyengaged on the camshaft nose taper, yet looseenough so it can rotate on the camshaft nose.

Install the tone wheel and capscrew, makingsure that the key on the tone wheel matches upproperly with the keyed hole in the camshaft.

Hand-tighten the capscrew and then loosen byone “flat,” which is 60 degrees.

NOTE: The valve camshaft gear is still looseat this point to allow the adjustable idlergear to be properly positioned. Do not seatthe gear.


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The lower idler scissor gear must still beunloaded during this step. To unload the gear,two of the gear adjusting screws must bebacked out far enough to allow the teeth on thescissor gear to be aligned.

Insert, as illustrated, a narrow shim (0.25 mm[0.010 in]) into the gear teeth mesh between thecamshaft idler gear and the upper idler gear, aswell as a narrow shim (0.25 mm [0.010 in]) intothe mesh between the camshaft idler gear andthe valve camshaft gear.

NOTE: Per the above adjustable idler gearinstall procedure, be sure that the oil hole inthe retainer plate and the shaft are in linewith the oil drilling in the head. Use thecamshaft idler gear retainer markings toinsert the feeler gauges in the correct teethmesh. The triangles represent idler gearteeth. The lines represent the feeler gaugeplacement.

Shim Tolerance

mm in0.225 MIN 0.0090.275 MAX 0.011

Use hand pressure only, to move the camshaftidler gear toward the center of the engine androtate the cam gear clockwise (into mesh), sothere is no gap on either side of the shim.

A slight drag will be felt on the shims while


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pulling the shims in and out. Do not remove theshims.

Hold the adjustable camshaft idler gear inposition and tighten the capscrews. Use thealternating pattern shown in the illustration.

Tighten all capscrews in an alternating pattern.

Tighten the camshaft idler gear mountingcapscrews: 30 N•m [22 ft-lb].

1.

Tighten the valve camshaft gear mountingcapscrew: 30 N•m [22 ft-lb].

2.

Rotate the camshaft idler gear mountingcapscrews an additional 60 degrees.

3.

Tighten the valve camshaft gear mountingcapscrew: 148 N•m [109 ft-lb]

4.

Remove the shims.

A slight drag should be felt on the shims whilepulling the shims out.

Make sure all the scissor gear screws aretightened to the proper torque so that they donot back out during engine operation. Severeengine damage can occur.

NOTE: If the fuel pump and air compressorhave been removed, do not perform theselast three steps until the fuel pump and air


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compressor have been installed.

The lower idler scissor gear must not beloaded until all other gears are installed andtightened.

Load the lower idler scissor gear by tighteningall of the gear adjusting screws.


Coat the entire gear train with clean 15W-40 oil.

Remove the valve camshaft timing wedge.

A sudden jerking motion upward is the mosteffective way to remove the wedge.

Remove the crankshaft locking pin.

Install the plug into the timing pin boss hole.

Torque Value: 20 n.m [177 in-lb]


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Rotate the crankshaft over 360 degrees.

Check the fuel pump idler gear capscrews.

Tighten the fuel pump idler gear capscrews.


If any of the capscrews rotate prior to achievingthe above torque value:

Loosen all three capscrewsTighten the capscrews. Use the methodspecified in the Install Step of thisprocedure for the fuel pump idler gear.

Install the camshaft position sensor. Referto Procedure 019-363 in Section 19.Install the upper gear cover. Refer toProcedure 001-079 in Section 1.Install the crankshaft position sensor.Refer to Procedure 019-365 in Section 19.Install the lower gear cover. Refer toProcedure 001-080 in Section 1.Install the rocker lever cover and gasket.Refer to Procedure 003-011 in Section 3.Install the EGR crossover tube. Refer toProcedure 011-070 in Section 11.If coolant, oil, excessive fuel, or excessiveblack smoke has entered the exhaustsystem, the aftertreatment system mustbe inspected.

Use the following procedure tocheck the aftertreatment selectivecatalytic reduction. Refer toProcedure 014-015 in Section 14.


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Use the following procedure tocheck the aftertreatment dieselparticulate filter. Refer to Procedure014-016 in Section 14.

Operate the engine to normal operatingtemperature and check for leaks andproper operation.

Last Modified: 14-Jan-2016

Copyright © 2000-2010 Cummins Inc. All rights reserved.


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