Camshafts

REAR GEAR GROUP

REMOVE REAR GEAR GROUP 1212-11

Tools Needed A 1P520Driver Group 1

start by: a) remove flywheel housing

NOTE: Before the flywheel housing is removed, the 3508 engine must be put in time to make sure the rear gear group is in alignment according to the rotation of the engine as shown.

1. Remove plate (1) to remove gear assembly (2) from the shaft.

2. Use tool group (A) and a press to remove bearing (3) from gear assembly (2).

3. Use tool group (A) and a press to make a separation of the gears for gear assembly (2).

4. Remove the bolts to remove the shafts, gears (4) and the washers from the cylinder block.

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REAR GEAR GROUP

5. Remove washers (6) and shafts (5) from gears (4).

6. Use tool group (A) and a press to remove the bearings from gears (4). Remove shaft (7) from engine.

7. Remove the bolts and remove gear (8) from the end of the crankshaft.

INSTALL REAR GEAR GROUP 1212-12

Tools Needed A 1P520Driver Group 1

1. Put gear (1) in position on the end of the crankshaft and install the bolts.

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REAR GEAR GROUP

2. Install shaft (2) on the cylinder block.

3. Use tool group (A) and a press to install the bearings in both gears (3) until the bearings are in the center of their bores. The bore in the bearing must be 75.00 ± 0.053 mm (2.9528 ± .0021 in.) after assembly.

4. Put clean engine oil on the bearings and install shafts (5) in gears (3). Install washers (4) on the shafts.

5. Put gears (3) in position on the cylinder block and install the bolts to hold the gears in position.

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REAR GEAR GROUP

6. Use tool group (A) and a press to install bearing (6) in gear assembly (7). The bore in bearing (6) must be 75.00 ± 0.053 mm (2.9528 ± .0021 in.) after assembly.

7. Heat the larger gear of gear assembly (7) to a maximum temperature of 400° C (752° F) and install it on the smaller gear as shown.

8. Put clean engine oil on the bearing and install gear assembly (7) on the shaft.

NOTE: Step 9 is for the 3508 Engine.

9. Put clean engine oil on the bearing and install the gear assembly on the shaft. Make sure the marks on the gear assembly and the crankshaft gear are in alignment according to the rotation of the engine as shown.

10. Put plate (8) in position on gear assembly (7) and install the bolts. end by: a) install flywheel housing

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SPACER PLATES

REMOVE SPACER PLATES 1221-11

start by: a) remove cylinder heads

1. Remove gasket (4), seals (1), seals (2) and Oring seal (3) from the spacer plate.

2. Remove spacer plate (5) from the dowels in the cylinder block.

3. Remove gasket (6) from the dowels.

4. Remove the O-ring seal from around dowel (7).

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SPACER PLATES

INSTALL SPACER PLATES 1221-12

1. Make sure the spacer plate and the machined surface of the cylinder block are clean and free of dirt and foreign material.

2. Install the O-ring seal around dowel (2).

NOTICE Both surfaces of the spacer plate gasket and the top of the cylinder block must be clean. Do not use a gasket adhesive on these surfaces.

3. Install new spacer plate gasket (1) over the dowels in the cylinder block.

4. Install spacer plate (3) on the dowels.

5. Install the O-ring seal around dowel (5).

6. Install new water seals (4) and (6) in spacer plate (3).

7. Install new cylinder head gasket (7) on the spacer plate.

8. Check the cylinder liner projection. See INSTALL CYLINDER LINERS. end by: a) install cylinder heads

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CRANKSHAFT MAIN BEARINGS

REMOVE CRANKSHAFT MAIN BEARINGS 1203-11

Tools Needed A B

C 9S9082 Engine Turning Tool 1 6V3147 Main Bearing Wrench 1 2P5517 Bearing Removal and Installation Tool

1

start by: a) remove piston cooling jets

1. Drain the oil from the oil pan.

2. Use tool (A) to turn the engine flywheel to move counterweights (1) in position for removal. Remove counterweights (1) from the crankshaft through the side of the cylinder block.

3. Use tool (A) and turn the engine flywheel to move the connecting rod bearing surface (journal) to the top center position.

4. Use tool (B) and loosen the four bolts that hold the main bearing cap in position.

5. Hold the main bearing cap in position with a pry bar and remove the bolts and lower the bearing cap from the cylinder block.

6. Remove the bearing caps from the side of the engine. The weight of the bearing cap is 16 kg (35 lb.).

7. Remove the lower bearing half (2) from bearing cap (3). 8. Remove thrust plates (4) from each side of the center main bearing.

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