9/1/2019 QuickServe Online | (4022250) ISX15 CM2250 Service Manual

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Install
 CAUTION 
The timing pin and wedge must be installed before any
gears are removed and must remain in place until all
gears are fully installed and tightened. Failure to install
the timing pin and wedge can lead to improper timing of
the engine, resulting in severe engine damage or engine
failure.

 CAUTION 
The gear train must be assembled in the same sequence as this procedure lists. Failure to
follow this sequence may result in severe engine damage.

If only one gear is removed and installed:

It is necessary to measure gear backlash after installing gear.
If the valve camshaft gear, camshaft idler gear, or fuel pump gear is removed and installed:
It is necessary to adjust gear backlash after installing gears.
If only the fuel pump gear is removed and installed:
Measurement or adjustment of backlash is not needed.
If removing more than one gear:
Installation order is critical. See ordered steps below.
Adjust gear backlash after installing gears.
Perform a rotation check.

Lower Idler Solid Gear

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 CAUTION 
The lower idler gear thrust bearing plate and shaft must
be oriented such that the oil drain from the head is not
blocked. If blocked, engine operation will be affected.

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

gear.
Install the thrust bearing plate, shaft, and lower idler gear. The
shaft must be installed with the word “TOP” (stamped on the
end of the shaft) toward the top of the engine.
Verify the hole in the thrust bearing plate, shaft, and retainer
plate are in line with the oil drilling in the block.

The slots in the gear retainer plate face toward the gear.
Install the retainer plate and capscrews.

Tighten all capscrews in the alternating pattern shown in the

illustration.
Torque Value:
1. 70 n•m [ 52 ft-lb ]
2. Rotate each capscrew an additional 60 degrees ±
5 degrees in the same alternating patterns.

Lower Idler Scissor Gear

 CAUTION 
Do not attempt to remove any gears before reading
scissor gear definitions. Serious personal injury can
result if instructions are not followed.

 CAUTION 
Do not attempt to remove any gears before reading
scissor gear definitions. Engine damage can result if
instructions are not followed.

The lower scissor idler gear must be unloaded during

installation. To unload the gear, two of the gear adjusting
screws must be backed out far enough to allow the teeth on

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the scissor gear to be aligned.

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

Install the thrust bearing, shaft, and lower scissor idler gear.
The shaft must be installed with the word “TOP” (stamped on
the end of the shaft) toward the top of the engine.

The slots in the gear retainer plate face toward the scissor
gear.
Install the retainer and capscrews.

Tighten all capscrews in the alternating pattern shown in the

illustration.
Torque Value:
1. 70 n•m [ 52 ft-lb ]
2. Rotate each capscrew an additional 60 degrees ±
5 degrees in the same alternating patterns.
Note : The lower idler scissor gear must not be loaded
until all other gears are installed and tightened.

Upper Idler Gear

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

The spacer plate/shaft assembly is doweled to the block with

two standard dowels.
Install the mounting spacer plate/shaft assembly and the upper
idler gear.

The spacer plate/shaft assembly must be installed with the

work "OIL PAN", stamped on the front face of the shaft,
oriented toward the oil pan.

The slots (1) in the gear retainer plate face toward the gear.

Install the retainer and capscrews.

Tighten all capscrews in the alternating pattern as shown in the

illustration.

Torque Value:
1. 88 n•m [ 65 ft-lb ]

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2. Rotate each capscrew an additional 60 degrees ±

5 degrees in the same alternating patterns.

Accessory Drive Gear

Camshaft Idler Gear (Adjustable)

 CAUTION 
The camshaft idler gear retainer and shaft must be
oriented with the part number facing outward, such that
the oil drain from the head is not blocked. If blocked,
engine operation will be affected.

Apply Lubriplate™ to the shaft and camshaft idler gear.

Install the shaft and the adjustable camshaft idler gear. The
shaft must be installed with the words “OIL PAN” and the
arrow (stamped on the front face of the shaft) pointing toward
the oil pan.

The slots in the gear retainer plate face toward the gear.

Install the retainer and capscrews. Hand tighten the capscrews

and then loosen by one “flat,” which is 60 degrees.

Verify the oil hole in the retainer plate and shaft (1) is in line
with the oil drilling in the head.
Note : The camshaft idler gear is installed loosely. It is
moved into its final position later in the timing process.

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Valve Camshaft Gear

 WARNING 
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer’s recommendations for
use. Wear goggles and protective clothing to reduce the
possibility of personal injury.

 CAUTION 
The valve camshaft nose and valve camshaft gear must
be clean and dry prior to assembly. Wipe off the shaft
surface and gear with a lint-free cloth and do not touch
the surfaces after wiping. Engine damage can occur.

 CAUTION 
The camshaft gear retaining capscrew torque process
must be completed within fifteen (15) minutes of Loctite®
application or severe engine damage may occur.

Scrape off any Loctite® residue from the bore of the valve
camshaft gear.

Clean the valve camshaft and camshaft gear bore with

Envirosol™ 655 solvent, or equivalent, and a lint-free cloth.

Do not spray solvent directly onto the camshaft nose. Spray

solvent onto a clean, lint-free cloth, and then wipe the
camshaft nose clean. No oil residue can remain and these
surfaces are not to be touched once cleaned.
Apply a thin coat of Loctite® 609, Part Number 3823718, to the
camshaft nose and camshaft gear bore.

Install the valve camshaft gear loosely on the camshaft nose

taper.

The valve camshaft gear needs to be fully engaged on the

camshaft nose taper, yet loose enough so it can rotate on the
camshaft nose.
Install the tone wheel and capscrew.

Verify that the key on the tone wheel matches up properly with
the keyed hole in the camshaft.
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Hand tighten the capscrew and then loosen by one “flat,” which
is 60 degrees.
Note : The valve camshaft gear is still loose at this point
to allow the adjustable idler gear to be properly
positioned. Do not seat the gear.

Adjust
Camshaft Idler Gear (Adjustable)
Insert, as illustrated, a narrow shim (0.1016 mm [0.004 in]) into
the gear teeth mesh between the camshaft idler gear and the
upper idler gear, as well as a narrow shim (0.1016 mm [0.004
in]) into the mesh between the camshaft idler gear and the
valve camshaft gear.
Note : Per the above adjustable idler gear install
procedure, verify the oil hole in the retainer plate and
the shaft are in line with the oil drilling in the head. Use
the camshaft idler gear retainer markings to insert the
feeler gauges in the correct teeth mesh. The triangles
represent idler gear teeth. The lines represent the feeler
gauge placement.
Shim Tolerance
mm in
0.0762 MIN 0.003
0.1016 MAX 0.004

Use hand pressure only to move the camshaft idler gear

toward the center of the engine and rotate the cam gear
clockwise (into mesh), so there is no gap on either side of the
shim.

A slight drag will be felt on the shims while pulling the shims in
and out. Do not remove the shims.

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Hold the adjustable camshaft idler gear in position and tighten

the capscrews. Use the alternating pattern shown in the
illustration.

Tighten all capscrews in an alternating pattern.

1. Tighten the camshaft idler gear mounting capscrews: 30
N•m [22 ft-lb].
2. Tighten the valve camshaft gear mounting capscrew: 30
N•m [22 ft-lb].
3. Rotate the camshaft idler gear mounting capscrews an
additional 60 degrees.
4. Tighten the valve camshaft gear mounting capscrew: 148
N•m [109 ft-lb]

Remove the shims.

A slight drag should be felt on the shims while pulling the
shims out.

Fuel Pump Idler Gear

Note : The adjustable fuel pump must be installed and

timed correctly before installing the fuel pump idler gear.
Use the following procedure for fuel pump installation and
timing. Refer to Procedure 005-016 in Section 5.
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Apply Lubriplate™ to the thrust bearing plate, shaft, and fuel
pump idler gear. Align all components in order shown in the
illustration.

 CAUTION 
The adjustable fuel pump idler gear thrust bearing plate
and shaft must be oriented such that the oil drain from
the head is not blocked. If blocked, engine operation will
be affected.

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Replace the capscrews with new ones. Chase the internal

threads of the block.

With new capscrews, verify the capscrews have pre-applied

threadlocker or add threadlocker as specified.

If using plain capscrews, apply Loctite® 242, Part Number

3824040 or 3824041, to the threads of the fuel pump idler gear
capscrews.

Install the adjustable fuel pump idler gear assembly to the

cylinder block. The correct order from cylinder block out: thrust
bearing plate (markings facing toward the gear), fuel pump
idler gear, shaft, and retainer plate assembly.
The gear should be installed with the word "Pan" and
arrow pointing toward the oil pan.
The shaft must be installed with the alignment marks
pointed toward the center of the lower idler gear and
pointed toward the center of the fuel pump gear.
Use the guide pins to start capscrews onto gear housing.
Note : This piece (1) is only on the adjustable idler gear.

 CAUTION 
The adjustable fuel pump idler gear retaining capscrew
torque process must be completed within fifteen minutes
of the initial threading or severe engine damage can
occur. If disturbed after fifteen minutes, the capscrews
must be cleaned and new medium strength threadlocker
applied or use new pre-coated capscrews.

Install and tighten capscrews.

Hand tighten the capscrews. Loosen 60 degrees.

 CAUTION 
If the adjustable fuel pump idler gear mesh setting is
beyond tolerances, it can lead to improper engine
function or engine failure.

Adjustable Fuel Pump Idler Gear

Insert narrow or tapered shims at the points illustrated:

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0.1016 mm [0.004 in] into the gear teeth mesh between

the lower idler gear and fuel pump idler gear
0.1016 mm [0.004 in] into the mesh between the fuel
pump idler gear and fuel pump gear.
Note : Use the fuel pump idler gear shaft retainer
markings as a guide to correct feeler gauge placement.
The triangles represent idler gear teeth. The lines
represent the feeler gauge.
Shim Tolerance
mm in
0.0762 MIN 0.003
0.1016 MAX 0.004

Move the fuel pump idler gear toward the center of the engine
so there is no gap on either side of the shims.
Use a pry bar and the gear train housing to rotate the fuel
pump gear clockwise and hold the fuel pump idler gear mesh
in position.
Note : The fuel pump idler gear is in mesh when a slight
drag can be felt on the shims while pulling the shims in
and out. Do not remove the shims.

Hold the adjustable fuel pump idler gear in position. Tighten

the capscrews. Use the pattern shown in the illustration.

Torque Value:
1. 35 n•m [ 26 ft-lb ]
2. Rotate each capscrew an additional 60 degrees in
the sequence shown.
Remove the shims.

Non-Adjustable Fuel Pump Idler Gear

Confirm the fuel pump is timed correctly before installing fuel

pump idler gear. Refer to Procedure 005-016 in Section 5.
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Apply Lubriplate™ to the thrust bearing, shaft, and fuel pump
idler gear.

Remove any Loctite® residue. Chase the internal threads.

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Use new capscrews.

With new capscrews, verify the capscrews have pre-applied
threadlocker or add threadlocker as specified.
If using plain capscrews, apply Loctite® 242, Part Number
3824040 or 3824041, to the threads of the fuel pump idler gear
capscrews.
Install the thrust bearing, shaft, and fuel pump idler gear. The
shaft must be installed with the alignment make (1) (stamped
on the gear retainer) pointed toward the center of the lower
idler scissor gear.

 CAUTION 
The fuel pump idler gear retaining capscrew torque
sequence (including torque check) must be completed
within 15 minutes of the initial threading or severe engine
damage can occur. If disturbed after 15 minutes, the
capscrews must be cleaned and new medium strength
threadlocker applied, or use new pre-coated capscrews.

Install the capscrews.

Tighten all capscrews evenly.

Torque Value:
1. 35 n•m [ 26 ft-lb ]
2. Rotate each capscrew an additional 60 degrees in
the same sequence, as shown.

Do not load the lower idler scissor gear, if equipped, until all
other gears are installed and tightened.

Load the lower idler scissor gear, if equipped, by tightening all

of the gear adjusting screws.

Torque Value: 29 n•m [ 21 ft-lb ]

 CAUTION 
Verify all gear screws are tightened to the proper torque
so they do no back out during engine operation. Severe
engine damage can occur.

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Note : If the fuel pump and air compressor have been

removed, do not perform these last three steps until the
fuel pump and air compressor have been installed.
Coat the entire gear train with clean 15W-40 engine oil.

Remove the valve camshaft timing wedge.

A sudden jerking motion upward is the most effective 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 ]

Rotation Check
Note : Recheck limit is not the total of both clearances.
Rotate the crankshaft over 360 degrees.
Using feeler gauges, check the gear lash between the
following gears:
Fuel pump idler gear to fuel pump gear
Fuel pump idler gear to lower idler gear.

Mesh Tolerance
mm in
0.0508 MIN 0.002
0.1524 MAX 0.006

The mesh tolerance recheck limits in the table is not the total
of both measurements.
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Check the torque on the fuel pump idler gear capscrews.

Tighten the fuel pump idler gear capscrews.

Torque Value: 70 n•m [ 52 ft-lb ]

If any of the capscrews rotate prior to achieving the above
torque value:
Loosen all three capscrews
Tighten the capscrews. Use the method specified in the
Install Step of this procedure for the fuel pump idler gear.

Last Modified: 07-May-2019

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