C6.6 Industrial Engine Idler Gear - Install Caterpillar


Idler Gear - Install
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1.1. Installation Procedure

Installation Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
364-9107  Timing Pin (Fuel Injection Pump) 
230-6284  Timing Pin (Camshaft) 
136-4632  Timing Pin (Crankshaft) 
298-5564  T40 Torx Socket 
9U-7324  Indicator Bracket 
7H-1942 Dial Indicator 
3S-3268 Indicator Contact Point 
7H-1940 Universal Attachment 


NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shorten component life.




    Illustration 1g01996476


    Illustration 2g01996475

  1. 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 Center Position for No.1 Piston" for the correct procedure.

  2. Ensure that Tooling (B) is installed into Hole (X) in camshaft gear (3).

  3. Use Tooling (A) in order to lock the fuel injection pump gear in the correct position. Refer to Disassembly and Assembly, "Fuel Injection Pump - Remove" for the correct procedure.


    Illustration 3g01996477


    Illustration 4g02196594


    Illustration 5g01996576

  4. Clean idler gear (4) and inspect the idler gear for wear and damage. Refer to Specifications, "Gear Group (Front)" for more information. If necessary, replace the idler gear.

  5. Clean hub (9) and inspect the hub for wear and damage. Refer to Specifications, "Gear Group (Front)" for more information. If necessary, replace the hub.

  6. Lubricate hub (9) with clean engine oil. Install hub (9) into the recess in the front housing. Ensure that oil Hole (Z) is position as shown in the Illustration 4.

  7. Install idler gear (4) onto hub (9). Ensure that the timing marks are toward the front of the idler gear.

  8. Align the timing mark on idler gear (4) with the timing mark on camshaft gear (3), fuel injection pump gear (10) and crankshaft gear (11). Refer to the Illustration 5. Install the assembly of idler gear (4) to hub (9).

  9. Clean plate (8) and inspect the plate for wear and damage. If necessary, replace the plate.

  10. Lubricate plate (8) with clean engine oil. Align the holes in plate (8) with the holes in hub (9). Install the plate in the original orientation.

    Note: Ensure that the identification mark TOP is upward.

  11. Install bolts (7). Tighten the bolts to a torque of 44 N·m (32 lb ft).

  12. Remove Tooling (A), Tooling (B), and Tooling (C).

    Note: Ensure that timing marks are aligned, before removing the Tooling (A), Tooling (B) and Tooling (C).



    Illustration 6g01996554

  13. Position a new O-ring seal (1) onto plug (2). Install the plug to the cylinder block and tighten the plug to a torque of 21 N·m (186 lb in).

  14. Use Tooling (E) in order to check the end play for the idler gear. Refer to Specifications, "Gear Group (Front)" for more information.

  15. Use Tooling (E) in order to check the backlash between the idler gear and the camshaft gear. Refer to Specifications, "Gear Group (Front)" for more information.

  16. Use Tooling (E) in order to check the backlash between the idler gear and the crankshaft gear. Refer to Specifications, "Gear Group (Front)" for more information.

  17. Use Tooling (E) in order to check the backlash between the idler gear and the fuel injection pump gear. Refer to Specifications, "Gear Group (Front)" for more information.

  18. Lightly lubricate all of the gears with clean engine oil.


    Illustration 7g01994556

  19. Rotate the crankshaft in a clockwise direction and position the crankshaft at 60 degrees after top dead center. Refer to System Operation, Testing and Adjusting, "Position the Valve Mechanism Before Maintenance Procedures" for the correct procedure.

  20. Use Tooling (D) in order to tighten threaded inserts (4) on all rocker arms (5). Tighten the threaded inserts to a torque of 30 N·m (266 lb in).

    Note: When the threaded insert is tightened, the threaded insert must be seated correctly into the cup for the pushrod.

  21. The engine should not be operated for a period 30 minutes after the threaded inserts on all the rocker arms have been tightened. This period will allow the force from the valve springs to purge off excessive engine oil from the hydraulic lifters.

End By:

  1. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure.

  2. Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure.

Information System:

C6.6 Industrial Engine Idler Gear - Remove
C6.6 Industrial Engine Gear Group (Front) - Remove and Install - Heavy Duty Gear Group (Front)
C6.6 Industrial Engine Gear Group (Front) - Remove and Install
C6.6 Industrial Engine Crankshaft Front Seal - Remove and Install - Crankshaft Front Seal for Heavy Duty Front Cover
C6.6 Industrial Engine Crankshaft Front Seal - Remove and Install
C4.4 Industrial Engine Engine Oil Pump
C6.6 Industrial Engine Vibration Damper and Pulley - Install
C6.6 Industrial Engine Vibration Damper and Pulley - Remove
MP15, MP20, MP30 and MP40 Multi-Processors Wear Plates - Inspect/Replace
MP15, MP20, MP30 and MP40 Multi-Processors Rotator Head Bolts - Inspect
MP15, MP20, MP30 and MP40 Multi-Processors Rotator Head Bolts - Inspect
C15 and C18 Tier 4 Final Engines Exhaust Cooler (NRS) - Test
C6.6 Industrial Engine Housing (Front) - Remove
C6.6 Industrial Engine Housing (Front) - Remove - Heavy Duty Housing (Front)
2010/05/13 The Gas Strut on Backhoe Loader Steering Columns Has Been Improved {4309, 4310, 4338}
C6.6 Industrial Engine Housing (Front) - Install
C6.6 Industrial Engine Housing (Front) - Install - Heavy Duty Housing (Front)
C6.6 Industrial Engine Accessory Drive - Remove and Install - Accessory Drive SAE "A"
C6.6 Industrial Engine Accessory Drive - Remove and Install - Accessory Drive SAE "B"
C6.6 Industrial Engine Crankcase Breather - Remove
C6.6 Industrial Engine Crankcase Breather - Install
C6.6 Industrial Engine Valve Mechanism Cover - Remove and Install
C13 Engines for Caterpillar Built Machines Temperature Sensor (DPF Inlet, Flame Detect)
C6.6 Industrial Engine Rocker Shaft and Pushrod - Remove