ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 001-033   Gear Housing, Front

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

WARNING  Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment and switches out of the work area and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel system.

• Disconnect the batteries. Refer to Procedure 013-009 in Section 13.
• Shut off the fuel supply. Refer to the OEM service manual.
• Remove the rubber vibration damper, if installed. Refer to Procedure 001-051 in Section 1.
• Remove the viscous vibration damper, if installed. Refer to Procedure 001-052 in Section 1.
• Remove the gear cover. Refer to Procedure 001-031 in Section 1.
• Remove the rocker lever cover. Refer to Procedure 003-011 in Section 3.
• Remove the rocker levers. Refer to Procedure 003-008 in Section 3.
• Remove the push rods. Refer to Procedure 004-014 in Section 4.
• Remove the fuel pump. Refer to Procedure 005-016 in Section 5.
• Remove the camshaft gear. Refer to Procedure 001-012 in Section 1.
• Remove the camshaft if the camshaft gear can not be removed. Refer to Procedure 001-008 in Section 1.
• Remove or disconnect gear driven accessories, such as air compressor and hydraulic pump.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

WARNING  Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment and switches out of the work area and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel system.

CAUTION  Use caution when draining the fuel system that fuel is not spilled or drained into the bilge area. The fuel must be disposed of in accordance with local environmental regulations.

• Shut off the fuel supply. Refer to the OEM service manual.
• Shut off the sea water supply. Refer to the OEM service manual.
• Disconnect the batteries. Refer to Procedure 013-009 in Section 13.
• Remove the fuel filter mounting bracket. Refer to Procedure 006-018 in Section 6.
• Remove the rocker lever cover. Refer to Procedure 003-011 in Section 3.
• Remove the rocker levers. Refer to Procedure 003-008 in Section 3.
• Remove the push rods. Refer to Procedure 004-014 in Section 4.
• Remove the belt guard. Refer to Procedure 008-001 in Section 8.
• Remove the drive belt. Refer to Procedure 008-002 in Section 8.
• Remove the automatic belt tensioner, if required. Refer to Procedure 008-080 in Section 8.
• Remove the vibration damper, if installed. Refer to Procedure 001-052 in Section 1.
• Remove the gear cover. Refer to Procedure 001-031 in Section 1.
• Remove the fuel pump. Refer to Procedure 005-016 in Section 5.
• Remove the camshaft gear. Refer to Procedure 001-012 in Section 1.
• Remove the sea water pump, if equipped. Refer to Procedure 008-057 in Section 8.

Remove the four front oil pan capscrews.

Remove the gear housing capscrews.

Use a feeler gauge to separate the lubricating oil pan gasket from the gear housing.

Remove the gear housing capscrews and remove the gear housing.

Clean the gasket material from the cylinder block.

Inspect the lubricating oil pan gasket for tears or other damage. See the Install section of this procedure if the gasket is damaged.

Inspect fuel pump mounting studs for damage.

To install or remove the fuel pump studs, use two nuts locked together on the stud.

Inspect the gear housing sealing surfaces for cracks or other damage. Replace the gear housing if any damage is found.

Pan Gasket – Repair

If the lubricating oil pan gasket is damaged, it can be repaired.

Cut the damaged gasket off even with the front of the cylinder block.

Use the old gasket as a template to cut the front section of a new gasket to the same size.

NOTE: The gear housing must be installed within 10 minutes of applying the sealant.

Clean the sealing surfaces.

Coat the new gasket on both sides with RTV sealant, Part Number 3823494 or equivalent.

Be sure there is a bead of sealant at the intersecting joint of the cylinder block, oil pan, and gear housing.

Use common thread or a very fine wire to hold the new gasket splice in position as illustrated.

Position the gear housing gasket on the alignment dowels.

Use guide pins (M8 x 1.25 x 50) to assist in aligning the gasket and gear housing. Be sure to remove the guide pins after alignment.

Install the gear housing.

Start the oil pan capscrews in the holes not being used to tie the gasket in place.

Remove the thread or wire holding the gasket in place.

Install the remaining two oil pan capscrews and tighten. Refer to Procedure 007-025 in Section 7.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

WARNING  Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment and switches out of the work area and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel system.

• Install the camshaft, if removed. Refer to Procedure 001-008 in Section 1.
• Install the camshaft gear. Refer to Procedure 001-012 in Section 1.
• Install the push rods. Refer to Procedure 004-014 in Section 4.
• Install the rocker levers. Refer to Procedure 003-008 in Section 3.
• Adjust the overhead. Refer to Procedure 003-004 in Section 3.
• Install the rocker lever cover. Refer to Procedure 003-011 in Section 3.
• Install the gear cover. Refer to Procedure 001-031 in Section 1.
• Install the rubber vibration damper, if installed. Refer to Procedure 001-051 in Section 1.
• Install the viscous vibration damper, if installed. Refer to Procedure 001-052 in Section 1.
• Install the fuel pump. Refer to Procedure 005-016 in Section 5.
• Install or connect gear driven or accessories. Refer to the OEM service manual.
• Open the fuel valve. Refer to the OEM service manual.
• Connect the batteries. Refer to Procedure 013-009 in Section 13.
• Operate the engine and check for leaks.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

WARNING  Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment and switches out of the work area and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel system.

• Install the camshaft gear. Refer to Procedure 001-012 in Section 1.
• Install the sea water pump, if equipped. Refer to Procedure 008-057 in Section 8.
• Install the fuel pump. Refer to Procedure 005-016 in Section 5.
• Install the gear cover. Refer to Procedure 001-031 in Section 1.
• Install the seal carrier on the front cover. Refer to Procedure 001-023 in Section 1.
• Install the vibration damper, if installed. Refer to Procedure 001-052 in Section 1.
• Install the automatic belt tensioner, if removed. Refer to Procedure 008-080 in Section 8.
• Install the drive belt. Refer to Procedure 008-002 in Section 8.
• Install the belt guard. Refer to Procedure 008-001 in Section 8.
• Install the push rods. Refer to Procedure 004-014 in Section 4.
• Install the rocker levers. Refer to Procedure 003-008 in Section 3.
• Adjust the overhead. Refer to Procedure 003-004 in Section 3.
• Install the rocker lever cover. Refer to Procedure 003-011 in Section 3.
• Install the fuel filter mounting bracket. Refer to Procedure 006-018 in Section 6.
• Connect the batteries. Refer to Procedure 013-009 in Section 13.
• Open the fuel supply valve. Refer to the OEM service manual.
• Open the sea water supply valve. Refer to the OEM service manual.
• Operate the engine at idle for 5 to 10 minutes and check for leaks or loose parts.