5-14. GEAR COVER MAINTENANCE INSTRUCTIONS - Continued
Measure inside diameter of the camshaft bearing
Rotate the camshaft gear observing for the timing
bore with vernier caliper. Replace gear cover if
mark to appear and align with mark in the open-
bore diameter exceeds 2.4405 in. (61.991 mm).
ing for the compression release on top of gear
Install new gasket (14) to the mounting face of
Remove defective roll pins (15) by pulling out
the gear cover (13).
with a plier or vice grip. Install replacement roll
pin, tapping gently with hammer.
Lubricate the camshaft gear and exposed shaft
tip with engine lubricating oil, and carefully install
Replace a worn sleeve bushing (16) as follows:
the gear cover (13) onto the engine housing.
Care must be taken to ensure that the tip of the
Using an arbor press and a 18 mm diameter
camshaft engages bore of engine housing, while
pressing rod with a 16 mm pilot, press the
engaging camshaft gear teeth with teeth of crank-
sleeve bushing (16) through to the inside of
shaft gear without changing the alignment of tim-
the gear cover (13).
Using the same pressing rod and arbor press
install replacement bushing (16) into gear
If the position of the governor should pre-
cover (13). Seat the bushing flush with the
vent seating of the camshaft gear to the
outside surface of the gear cover.
crankshaft gear, turn the flywheel until its
timing mark aligns with threaded hole, ap-
proximately 1 o'clock on the engine hous-
ing. Turn the camshaft gear to offset the
timing mark exactly 3 teeth to the left of
the mark on edge of compression release
opening. Repeat step 8, maintaining this
The installation process depends on the
alignment. Rotate flywheel to TDC and
components/parts that were removed from
check camshaft timing mark for alignment
the gear cover. The procedure below pro-
with mark in the opening for the compres-
vides for complete installation to replace
sion release on top of gear cover (13).
the gear cover itself. Perform only those
If after installation of the gear cover the tim-
If removed, install the primer assembly (Para. 5-
ing mark of the flywheel is within ±0.0787
in. (±2 mm) of the mark on engine hous-
ing, the timing is correct.
If removed, install the camshaft bearing and cam-
After aligning roll pins (15) with respective bores
of the engine housing, gently tap around front
If removed, install the governor control lever and
edge of the gear cover with plastic hammer to
seat gear cover (13) to the engine housing.
If removed, install the injector fuel pump (Para.
10. Secure gear cover with six capscrews (11
and 12), installing the three longer capscrews
into the top two and bottom left holes. Tighten
Turn the flywheel to bring the piston to top dead
capscrews in a cross pattern, to 22 - 25 ft-lbs (29 -
center (TDC) by aligning the flywheel timing mark
34 Nm) with torque wrench fitted with 6 mm hex
with the mark stamped on the engine housing at
the 3 o'clock position