ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 001-012   Camshaft Gear (Camshaft Installed)

This procedure applies to engines with high-pressure common rail fuel system only.

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.

• Disconnect the batteries. Refer to Procedure 013-009 in Section 13.
• Remove the drive belt. Refer to Procedure 008-002 in Section 8.
• Remove the fan hub, if required. Refer to Procedure 008-039 in Section 8.
• Remove the vibration damper. 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.
• Loosen the rocker lever assemblies. Refer to Procedure 003-008 in Section 3.

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.

• Disconnect the batteries. Refer to Procedure 013-009.
• Remove the belt guard. Refer to Procedure 008-001 in Section 8.
• Remove the water pump drive belt. Refer to Procedure 008-002 in Section 8.
• Remove the water pump drive belt tensioner. Refer to Procedure 008-020 in Section 8.
• Loosen the fuel filter bracket and move it out of the way. Refer to Procedure 006-018 in Section 6.
• Remove the vibration damper. Refer to Procedure 001-052 in Section 1.
• Remove the front gear cover. Refer to Procedure 001-031 in Section 1.
• Remove the rocker lever cover. Refer to Procedure 003-011 in Section 3.
• Loosen the rocker lever assemblies. Refer to Procedure 003-008 in Section 3.

Use cam gear removal and installation tool, Part Number 3163054, and puller assembly, Part Number 3165093, to remove the camshaft gear from the camshaft.

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

Inspect the camshaft bore for fretting or burrs.

NOTE: If the fretting, burrs, or raised material can not be removed with abrasive pad, Part Number 3823258 or equivalent, replace the camshaft gear.

Inspect the camshaft gear keyway for burrs.

Remove burrs with abrasive pad, Part Number 3823258 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 fretting or burrs.

NOTE: If fretting or burrs can not be removed with abrasive pad, Part Number 3823258 or equivalent, replace the camshaft. Refer to Procedure 001-008 in Section 1.

Lubricate the camshaft surface with assembly lubricant, Part Number 3163087 or equivalent.

Install the key into the camshaft nose.

Tighten the thrust plate capscrews.

CAUTION  The camshaft gear will be permanently distorted if overheated. The oven temperature should never exceed 204°C [400°F].

Heat the camshaft gear for 45 minutes.

Use camshaft gear removal and installation tool, Part Number 3163054, and puller assembly, Part Number 3165093, to install the camshaft gear onto the camshaft.

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.

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

Use a 0.02 mm [0.001] feeler gauge, to see if the feeler gauge can be inserted between the camshaft gear and the shoulder on the camshaft. Insert the feeler gauge in multiple locations. If the feeler gauge can be inserted, the camshaft gear is not properly seated.

Using gauge, Part Number 3824564, and magnetic base, Part Number 3377399, verify the camshaft has proper backlash and end play.

Camshaft End Play (A)

Camshaft Gear Backlash Limits (B)

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.

• Install the gear cover. Refer to Procedure 001-031 in Section 1.
• Install the vibration damper. Refer to Procedure 001-052 in Section 1.
• Install the fan hub, if required. Refer to Procedure 008-039 in Section 8.
• Install the drive belt. Refer to Procedure 008-002 in Section 8.
• Tighten the rocker lever assemblies. Refer to Procedure 003-008 in Section 3.
• Adjust the valve lash. Refer to Procedure 003-004 in Section 3.
• Install the rocker lever cover. Refer to Procedure 003-011 in Section 3.
• Connect the batteries. Refer to Procedure 013-009 in Section 13.
• Operate the engine at idle for 5 to 10 minutes and check for leaks or loose parts.

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.

• Install the front gear cover. Refer to Procedure 001-031 in Section 1.
• Install the automatic belt tensioner. Refer to Procedure 008-080 in Section 8.
• Install the vibration damper. Refer to Procedure 001-052 in Section 1.
• Install the fuel filter head bracket. Refer to Procedure 006-018 in Section 6.
• Install the water pump drive belt. Refer to Procedure 008-002 in Section 8.
• Install the belt guards. Refer to Procedure 008-001 in Section 8.
• Tighten the rocker lever assemblies. Refer to Procedure 003-008 in Section 3.
• Adjust the valve lash. Refer to Procedure 003-004 in Section 3.
• Install the rocker lever cover. Refer to Procedure 003-011 in Section 3.
• Connect the batteries. Refer to Procedure 013-009 in Section 13.
• Operate the engine at idle for 5 to 10 minutes and check for leaks and loose parts.