M11 Series – Service Manual – 001-031   Gear Cover, Front

Remove the fan drive belt.

Refer to Procedure 008-002.

Remove the alternator drive belt.

Refer to Procedure 013-005.

NOTE: If the engine is equipped with an automatic belt tensioner, refer to Procedure 013-021 to remove the alternator belt.

Remove the fan and fan hub support.

Refer to Procedure 008-036.

If the engine is equipped with an automatic belt tensioner, remove the belt tensioner arm from the tensioner bracket.

Remove the four mounting capscrews and the tensioner bracket from the gear cover.

Remove the accessory drive pulley.

Refer to Procedure 009-004.

Remove the alternator drive pulley.

Refer to Procedure 009-010.

Remove the clamping plate, crankshaft pulley, and vibration damper.

Refer to Procedure 001-052.

WARNING  The lifting equipment must be designed to support the engine safely while the front engine support is removed from the engine. Failure to do so will result in equipment damage or personal injury.

Use an overhead hoist or hydraulic arm to support the engine.

Remove the capscrews that hold the front engine support to the cross
member of the equipment.

Remove the capscrews and the front engine support.

Remove the oil seals from the gear cover. Refer to the following:

Procedure 001-001,
Procedure 001-003,
and Procedure001-023.

Remove the remaining capscrews and the gear cover.

Remove the seal rings at the accessory drive mounting (1) and the water
pump mounting (2), and clean the grooves.

Remove the six o-ring seals at the crankshaft seal mounting (3), and
clean the grooves.

Remove the seal (4) from the front of the gear housing, and clean the groove.

Remove the o-ring at the front of the hydraulic drive idler retainer, and clean the groove.

WARNING  When using a steam cleaner, wear protective clothing, and safety glasses or a face shield. Hot steam can cause serious personal injury.

Clean the sealing surface on the rear face of the gear cover.

Clean the oil seal carrier gasket surfaces.

Use steam or solvent to clean the gear cover. Dry with compressed air.

Inspect the gear cover for cracks or damage.

If the cover is cracked, it

must be replaced.

Put the gear cover on a flat surface, and inspect the gear cover for flatness.

It is an acceptable practice to use a mallet to straighten a gear cover with minor bends.

Lay the gear cover on a flat surface, and hit the cover in the bent area.

Insert a new seal into the groove on the front of the gear housing.

Apply silicone sealant, Part No. 3823494, to the seal overlap joint
at the top of the gear housing.

Install a new seal ring at the accessory drive mounting (1) and water pump mounting (2) locations.

Install six new capscrew o-rings at the crankshaft seal mounting capscrew locations (3).

Install a new o-ring at the front of the hydraulic drive idler retainer
mounting spacer. Make sure the spacer is in place.

Install the gear cover and mounting capscrews.

NOTE: Do

not install the front engine support capscrews at this
time.

Tighten the capscrews.

NOTE: This is

not the final torque value.

If the engine is equipped with an automatic belt tensioner, install the belt tensioner bracket with the countersunk hole (A) facing away from the gear cover. Use a flat head (M8 x 25) at location (A).

Use three capscrews (M8 x 30) and plain washers at (B, C, and D). Tighten the capscrews.

NOTE: This is

not the final torque value.

Apply a coating of thread sealant, Part No. 3823494, to the three capscrews
at locations (1, 2, and 3).

Install and tighten all the front engine support and mounting capscrews
to the following torque:

NOTE: This is

not the final torque value.

Tighten the gear cover capscrews in the sequence shown.

Install the automatic belt tensioner with a (M10-1.50 x 70) capscrew. Align the cast locator pin on the tensioner with the hole in the bracket before tightening.

Lower the engine onto the crossmember.

Install the front support to crossmember.

Install the capscrews and tighten. Refer to the manufacturer’s specifications for the correct torque value.

Install the gear cover oil seals. Refer to the following:

Procedure 001-001,
Procedure 001-003,
and Procedure 001-023.

Install the vibration damper, crankshaft pulley, and clamping plate.

Refer to Procedure 001-052.

Install the alternator drive pulley.

Procedure 009-010.

Install the accessory drive pulley.

Procedure 009-004.

Install the fan hub support and fan.

Procedure 008-036.

Install and adjust the fan drive belt.

Procedure 008-002.

Install and adjust the alternator drive belt.

Procedure 013-005.

NOTE: If the engine is equipped with an automatic belt tensioner, refer to Procedure 013-021 to install the alternator belt.

Operate the engine to normal operating temperature and check for leaks.