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001-088 Engine Base Timing
General Information
Front Gear Assembly Configuration
This procedure describes the
removal, inspection, and
installation of the gear train.
The illustration shown is from
left to right and top to bottom.
Valve camshaft gear
Camshaft idler gear
(adjustable)
Upper idler gear
Lower idler scissor gear
Accessory drive gear
Fuel pump idler gear
Fuel pump gear.
Scissor Gear Definitions
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WARNING
Do not attempt to remove
any gears before reading
scissor gear definitions.
Serious personal injury or
engine damage can result if
instructions are not followed.
The following terms describe
the conditions of the scissor
gears for removal, installation,
and operation.
Unloaded
The gear will be
unloaded when
removing, installing,
and setting gear
backlash.
Unload the gear by
backing out two gear
adjusting screws until
the gear teeth align.
The idler scissor gear
is loaded after the gear
backlash is set.
Loaded
The gear teeth are
loaded (functional) and
are spread between
the mating gear teeth.
The gear is loaded by
tightening all of the
adjusting screws.
Torque
Value: 29 n.m [21 ft-lb]
The gear teeth will be
spread and no
movement will be felt
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against the crankshaft
gear. The gear will be
in the loaded condition
for engine operation.
Preparatory Steps
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.
Rotate the crankshaft
clockwise until the ”insert pin”
mark on the outside diameter
of the engine vibration damper
is aligned with the mark on the
gear housing. Refer to
Procedure 009-035 in Section
9.
Remove the plug from the
timing pin boss.
Insert the crankshaft locking
pin, Part Number 3163020,
into the timing pin boss hole.
The green band on the
timing pin will be lined up
with the surface of the timing
pin boss of the block.
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The pin is not correctly
seated in the crank notch if
the green band is either
completely visible outside
the block or is not visible at
all.
The crankshaft will be locked
in place when the pin is
properly seated.
Remove the exhaust
gas recirculation (EGR)
crossover tube. Refer
to Procedure 011-070
in Section 11.
Remove the rocker
lever cover and gasket.
Refer to Procedure
003-011 in Section 3.
The timing code is located on
the engine dataplate.
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WARNING
Do not drive the wedge into
place. Engine damage can
occur.
Insert the correct timing wedge
to lock the valve camshaft.
Lightly tap the top of the timing
wedge with a mallet to be sure
it is properly seated.
Make sure the wedge with the
proper angle is used and that
the wedge is properly seated in
its installed position.
Remove the camshaft
position sensor. Refer
to Procedure 019-363
in Section 19.
Remove the upper
gear cover. Refer to
Procedure 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.
Remove
Valve Camshaft Gear
The lower idler scissor gear
must be unloaded during
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removal of the valve
camshaft gear. To unload
the gear, two of the gear
adjusting screws must be
backed out far enough to
allow the teeth on the scissor
gear to be aligned.
Unload the lower idler
scissor gear.
Remove the valve camshaft
gear mounting capscrew and
the camshaft tone wheel.
NOTE: Do not disassemble
the camshaft tone wheel.
Install the gear puller, Part
Number 3163069.
Install the valve camshaft
gear mounting capscrew
completely.
Loosen the capscrew two
turns.
Use the gear puller to
remove the valve camshaft
gear from the camshaft
nose.
Remove the puller.
Do not completely remove
the camshaft gear mounting
capscrew when the three-
jaw puller is used. The
capscrew serves as a safety
catch by preventing the gear
from slipping off of the
camshaft's tapered nose.
Remove the valve camshaft
gear mounting capscrew,
spacer, and valve camshaft
gear.
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Camshaft Idler Gear (Adjustable)
The lower idler scissor gear
must be unloaded during
removal of any gears. To
unload the gear, two of the
gear adjusting screws must
be backed out far enough to
allow the teeth on the
scissor gear to be aligned.
Unload the lower idler
scissor gear.
CAUTION
The camshaft idler gear
shaft can fall out and be
damaged when the
camshaft idler gear is
removed.
Remove the retainer
capscrews, retainer, camshaft
idler gear, and idler gear shaft.
Upper Idler Gear
The lower idler scissor gear
must be unloaded during
removal of any gears. To
unload the gear, two of the
gear adjusting screws must
be backed out far enough to
allow the teeth on the scissor
gear to be aligned.
Unload the lower idler
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scissor gear.
Remove the retainer
capscrews, retainer, upper
idler gear, and spacer/shaft
assembly.
Accessory Drive Gear
If equipped, remove the air
compressor. Refer to
Procedure 012-014 in
Section 12.
Fuel Pump Idler Gear
The lower idler scissor gear
must be unloaded during
removal of any gears. To
unload the gear, two of the
gear adjusting screws must
be backed out far enough to
allow the teeth on the scissor
gear to be aligned.
Unload the lower idler
scissor gear.
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Remove the retaining
capscrews, shaft, fuel pump
idler gear, and thrust
bearing.
Lower Idler Scissor Gear
The lower idler scissor gear
must be unloaded during
removal of any gears. To
unload the gear, two of the
gear adjusting screws must
be backed out far enough to
allow the teeth on the scissor
gear to be aligned.
Unload the lower idler
scissor gear.
Remove the idler scissor
gear capscrews.
Remove the retainer, lower
idler scissor gear, shaft, and
thrust bearing.
Inspect for Reuse
Inspect the gear teeth on all
gears for pitting, heavy wear,
or breakage.
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Replace the suspect gear
and inspect the mating gear
for resulting damage.
Inspect the idler shafts for
heavy wear.
Measure the idler shafts
outside diameters.
Lower Idler Shaft Outside
Diameter
mm in
88.880 MIN 3.4992
88.894 MAX 3.4998
Upper Idler Shaft Outside
Diameter
mm in
88.880 MIN 3.4992
88.894 MAX 3.4998
Camshaft Idler Gear Shaft
Outside Diameter
mm in
95.343 MIN 3.7537
95.357 MAX 3.7542
Fuel Pump Idler Shaft
Outside Diameter
mm in
78.344 MIN 3.0844
78.358 MAX 3.0850
Inspect the idler gear bores
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for heavy wear or pitting.
Measure the inside diameter
of the lower idler gear,
adjustable idler gear,
camshaft idler gear, and fuel
pump idler gear bores.
Lower Idler Gear Bore
Inside Diameter
mm in
88.963 MIN 3.5025
88.989 MAX 3.5035
Adjustable Idler Gear
Bore Inside Diameter
mm in
88.963 MIN 3.5025
88.989 MAX 3.5035
Camshaft Idler Gear Bore
Inside Diameter
mm in
95.426 MIN 3.7569
95.452 MAX 3.7580
Fuel Pump Idler Gear
Bore Inside Diameter
mm in
78.426 MIN 3.0876
78.452 MAX 3.0887
Inspect the thrust bearing(s)
for pitting, cracking,
scratching, uneven wear, or
other damage. Replace the
thrust bearing(s) and inspect
the corresponding gear if
damage is found.
Install
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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 torqued. 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.
Fuel Pump Idler Gear
Be sure the fuel pump is
timed correctly before
installing the fuel pump idler
gear. Refer to Procedure
005-037 in Section 5.
Apply Lubriplate™ to the
thrust bearing, shaft, and
fuel pump idler gear.
Install the thrust bearing,
shaft, and fuel pump idler
gear. The shaft must be
installed with the alignment
mark (1) (stamped on the
gear retainer) pointed toward
the center of the lower idler
scissor gear.
Install the capscrews.
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Tighten all capscrews
evenly.
Torque Value:
1. 30 n.m [22 ft-lb]
2. Rotate each
capscrew an
additional 60
degrees in the same
sequence as above.
Lower Idler Scissor Gear
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 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 go toward the scissor
gear.
Install the retainer and
capscrews.
Tighten all capscrews in the
alternating pattern shown in
the illustration.
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Torque Value:
1. 30 n.m [22 ft-lb]
2. Rotate each
capscrew an
additional 60
degrees in the same
alternating patterns.
NOTE: The lower idler
scissor gear must not be
loaded until all other gears
are installed and
tightened.
Accessory Drive Gear
If equipped, install the air
compressor. Refer to
Procedure 012-014 in
Section 12.
Upper Idler Gear
Apply Lubriplate™ to the
spacer plate/shaft assembly
and the upper idler gear.
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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 word “OIL
PAN” (stamped on the front
face of the shaft) oriented
toward the oil pan.
The slots in the gear retainer
plate go toward the upper
idler gear
Install the retainer and
capscrews.
Tighten all capscrews in the
alternating pattern as shown
in the illustration.
Torque Value:
1. 30 n.m [22 ft-lb]
2. Rotate each
capscrew an
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additional 60
degrees in the same
alternating pattern.
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” (1) and the arrow
(stamped on the front face of
the shaft) pointing toward the
oil pan.
The slots in the gear retainer
plate go toward the gear.
Install the retainer and
capscrews. Hand-tighten the
capscrews and then loosen
by one “flat,” which is 60
degrees.
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Be sure that 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,
because it is moved into
its final position later in
the timing process.
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
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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, making sure that the
key on the tone wheel matches
up properly with the keyed hole
in the camshaft.
Hand-tighten the capscrew and
then loosen by one “flat,” which
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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
The lower idler scissor gear
must still be unloaded during
this step. To unload the gear,
two of the gear adjusting
screws must be backed out
far enough to allow the teeth
on the scissor gear to be
aligned.
Insert, as illustrated, a
narrow shim (0.25 mm [0.010
in]) into the gear teeth mesh
between the camshaft idler
gear and the upper idler
gear, as well as a narrow
shim (0.25 mm [0.010 in])
into the mesh between the
camshaft idler gear and the
valve camshaft gear.
NOTE: Per the above
adjustable idler gear install
procedure, be sure that the
oil hole in the retainer plate
and the shaft are in line
with the oil drilling in the
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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
0.225 MIN 0.009
0.275 MAX 0.011
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.
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].
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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.
CAUTION
Make sure all the scissor
gear screws are tightened
to the proper torque so that
they do not back out during
engine operation. Severe
engine damage can occur.
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.
The lower idler scissor gear
must not be loaded until all
other gears are installed and
tightened.
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Load the lower idler scissor
gear by tightening all of the
gear adjusting screws.
Torque
Value: 29 n.m [21 ft-lb]
Coat the entire gear train with
clean 15W-40 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]
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Rotation Check
Rotate the crankshaft over
360 degrees.
Check the fuel pump idler
gear capscrews.
Tighten the fuel pump idler
gear capscrews.
Torque
Value: 95 n.m [70 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.
Finishing Steps
Install the camshaft
position sensor. Refer
to Procedure 019-363
in Section 19.
Install the upper gear
cover. Refer to
Procedure 001-079 in
Section 1.
Install the crankshaft
position sensor. Refer
to Procedure 019-365
in Section 19.
Install the lower gear
cover. Refer to
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Procedure 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
to Procedure 011-070
in Section 11.
If coolant, oil,
excessive fuel, or
excessive black smoke
has entered the
exhaust system, the
aftertreatment system
must be inspected.
Use the following
procedure to
check the
aftertreatment
selective catalytic
reduction. Refer
to Procedure
014-015 in
Section 14.
Use the following
procedure to
check the
aftertreatment
diesel particulate
filter. Refer to
Procedure 014-
016 in Section
14.
Operate the engine to
normal operating
temperature and check
for leaks and proper
operation.
Last Modified: 09-Mar-2015
Copyright © 2000-2010 Cummins Inc. All rights reserved.
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