15.07.2023, 16:11 SIS 2.

2007/10/10 Camshaft Gear - Remove and Install (KENR6081-15)

SMCS - 1210 i02786892

Removal Procedure PIP

Table 1 -
202 1014
Required Tools

Tool Part Number Part Description

3
11: 07/1 261
/ 9 Qty
A(1) 9U-6198 1
KE 1:38+ 5
Crankshaft Turning Tool 1

A(2)
9U-7336
5P-7305
Housing
N
© 2 R60 05:00
Engine Turning Tool
1
1
B 230-6284
023 81
Timing Pin (Camshaft) 1

C
136-4632
Cat
Timing Pin (Crankshaft) 1
268-1966 Adapter
erp 1

illa
(1) The Crankshaft Turning Tool is used on the front pulley.

rI
(2) This Tool is used in the aperture for the electric starting motor.

Start By:
nc.
a. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve
Mechanism Cover - Remove and Install".

b. Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and
Install".

Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component

life.

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.
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Dispose of all fluids according to local regulations and

mandates.

1. Use Tooling (A) in order 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 Centre Position for No.1 Piston".

Illustration 1 g01340534

2. Install Tooling (B) through hole (X) in camshaft gear (1) into the front housing. Use Tooling
(B) in order to lock the camshaft in the correct position.

Illustration 2 g01335380

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3. Remove plug (4) from the cylinder block. Install Tooling (C) into hole (Y) in the cylinder
block. Use Tooling (C) in order to lock the crankshaft in the correct position.
Note: Do not use excessive force to install Tooling (C). Do not use Tooling (C) to hold the
crankshaft during repairs.

Illustration 3 g01340536

4. Loosen nuts (6) on all rocker arms (7). Unscrew adjusters (5) on all rocker arms (7) until all
valves are fully closed.
Note: Failure to ensure that all adjusters are fully unscrewed can result in contact between
the valves and pistons.

Illustration 4 g01340551
Alignment of timing marks

5. Mark gears (1) and (8) in order to show alignment. Refer to Illustration 4.
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Note: Identification will ensure that the gears can be installed in the original alignment.

Illustration 5 g01340554
6. Remove Tooling (B). Remove bolt (3) and washer (2) from camshaft gear (1).

7. Remove camshaft gear (1) from the camshaft.

Note: If the camshaft gear is a tight fit on the nose of the camshaft, use a prybar in order to
remove the camshaft gear.

8. If necessary, remove the key from the nose of the camshaft.

Installation Procedure
Table 2

Required Tools
Tool Part Number Part Name Qty
B 230-6284 Timing Pin (Camshaft) 1
136-4632 Timing Pin (Crankshaft) 1
C
268-1966 Adapter 1

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component

life.

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1. 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".

Illustration 6 g01335380

2. Ensure that Tooling (C) is installed in hole (Y) in the cylinder block. Use Tooling (C) in order
to lock the crankshaft in the correct position. Refer to System Operation, Testing and
Adjusting, "Finding Top Centre Position for No.1 Piston".

3. Ensure that the camshaft gear and the key are clean and free from wear or damage.

4. If necessary, install the key into the nose of the camshaft.

Note: Ensure that the key is squarely seated.

Illustration 7 g01340534

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Illustration 8 g01340551
Alignment of timing marks
5. Align the keyway in camshaft gear (1) with the key in the camshaft. Install camshaft gear
onto the camshaft. Ensure that the timing marks on gears (1) and (8) are in alignment and
that the mesh of the gears is correct. Refer to Illustration 8.

Illustration 9 g01340554

6. Install Tooling (B) through hole (X) in the camshaft gear into the front housing. Install washer
(2) and bolt (3) to camshaft gear (1).

7. Remove Tooling (B) and (C). Install plug (4) into hole (Y) in the cylinder block. Refer to
Illustration 6.

8. Tighten bolt (3) to a torque of 95 N·m (70 lb ft).

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Illustration 10 g01335426
9. Ensure that the backlash for gears (1) and (8) is within specified values. Refer to
Specifications, "Gear Group (Front)" for further information.

10. Ensure that the end play for camshaft gear (1) is within specified values. Refer to
Specifications, "Camshaft" for further information.

11. Lubricate the teeth of the gears with clean engine oil.

12. Adjust the valve lash. Refer to System Operation, Testing and Adjusting, "Engine Valve Lash
- Inspect/Adjust".

End By:

a. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and
Install".

b. Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism
Cover - Remove and Install".

PIP-10149261
2023/07/15
11:11:02+05:00
i02786892
© 2023 Caterpillar Inc.

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