B5.9G, B5.9LPG – Troubleshooting and Repair Manual – 001-013   Camshaft Gear (Camshaft Removed)

A camshaft gear removal/installation tool, Part Number 3823589, is available for replacing the camshaft gear in restricted areas where the camshaft can
not be removed from the engine. Follow the directions included with the tool.

Remove the fan pulley. Refer to Procedure
008-039.

Remove the vibration damper. Refer to Procedure
001-052.

Remove the gear cover. Refer to Procedure
001-031.

Remove the camshaft. Refer to Procedure
001-008.

CAUTION  Place a wooden block under the camshaft to avoid damage as the camshaft drops free from the cam gear.

Place the cam in a hydraulic press.

Press the gear off the shaft making sure the camshaft is supported.

Remove the Woodruff key.

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.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Use solvent to clean the camshaft gear.

Dry with compressed air.

Inspect the camshaft gear for cracked, chipped, or broken teeth.

Inspect the camshaft bore for frets or burrs.

NOTE: If the frets, burrs, or raised material can
not be removed with Scotch-Brite™ 7448, or equivalent, replace the camshaft gear.

Inspect the camshaft gear keyway for burrs.

Remove burrs with Scotch-Brite™ 7448, or equivalent.

NOTE: If the keyway is damaged or the burrs can
not be removed, the camshaft gear
must be replaced.

Inspect the camshaft nose for frets or burrs.

NOTE: If frets or burrs can
not be removed with Scotch-Brite 7448, or equivalent, replace the camshaft.

Use a leather hammer to install the Woodruff key.

Lubricate the camshaft surface with clean lubricating engine oil.

CAUTION  The camshaft gear will be permanently distorted if overheated. The oven temperature should never exceed 177°C [351°F].

Heat the camshaft gear in an oven at 149°C [300°F] for 45 minutes.

WARNING  Wear protective gloves to reduce the possibility of personal injury when handling parts that have been heated.

Install the camshaft gear with the timing marks away from the camshaft so they are visible from the outside of the engine block.

CAUTION  To reduce the possibility of engine damage, the timing marks and gear part numbers must be facing away from the camshaft when the gear is installed. Keep the camshaft in a vertical position with the gear up until the gear has cooled. Do not use water to reduce the cooling time. Using water can crack the gear.

NOTE: The gear
must be installed within 30 minutes after it is removed from the oven.

Remove the gear from the oven. Align the keyway in the gear with the dowel pin in the camshaft; install the gear on the camshaft. Make sure the gear is seated against the camshaft shoulder.

NOTE: Be sure the gear is seated against camshaft shoulder.

Using a 0.001-inch feeler gauge, check to see if the feeler gauge can be inserted between the camshaft gear and the shoulder on the camshaft. If the feeler gauge can be inserted, the camshaft gear is
not properly seated.

Install camshaft. Refer to Procedure
001-008.

Adjust the valve lash. Refer to Procedure
003-004.

Install gear cover. Refer to Procedure
001-031.

Install vibration damper. Refer to Procedure
001-052.

Install fan pulley. Refer to Procedure
008-039.