Do not operate or work on this engine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any AVSpare dealer for replacement manuals. Proper care is your responsibility.
Accidental engine starting can cause injury or death to personnel working on the equipment.
To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system.
Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.
|Camshaft Gear Bolt Torque||
Reference: Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston".
Reference: Testing and Adjusting, "Fuel Injector Adjustment".
Reference: Testing and Adjusting, "Valve Lash - Adjust" .
Use the procedures below to perform a timing check and timing adjustment.
|Item||Qty||Part Number||Part Name|
|T1||1||9S-9082||Engine Turning Tool|
- Turn off the engine.
Illustration 1 g00793695 Location of timing pins
(1) Timing hole
(2) Timing pin
- Remove the rear camshaft covers from both sides of the engine.
- Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston".
Note: When the timing bolt is installed, it is not necessary to remove the No. 1 valve cover to find the compression stroke. Both of the rear camshaft covers must be removed to check the timing.
- When the timing bolt is installed in the flywheel, look at the rear end of the camshaft. If the timing groove is visible, then the No. 1 piston is on the compression stroke. If the timing groove is not visible, then feel the back of the camshaft for the groove. If the groove is at the back of the camshaft, the flywheel must be turned by 360 degrees. Turning the flywheel for 360 degrees will put the No. 1 piston on the compression stroke.
Illustration 2 g00793673 Installation of timing pins
(2) Timing pin
(3) RH Camshaft
- Remove timing pins (2) from the storage positions after the timing bolt is installed in the flywheel. The engine must be on the No. 1 piston compression stroke.
- Install timing pins (2) through timing holes (1) in the engine block. Install timing pins (2) into the groove in camshaft (3) on each side of the engine. To time the engine correctly, the timing pins must fit into the groove of each camshaft.
- If timing pins (2) do not engage in the grooves of both camshafts, the engine is not in time. One camshaft or both camshafts must be adjusted.
- Both camshafts are adjusted in the same manner. Refer to "Timing Adjustment Procedure" for the procedure to put the camshafts in time with the crankshaft.
If a camshaft is out of time more than 18 degrees (approximately 1/2 the diameter of timing pin out of groove), the valves can make contact with the pistons. This will cause damage that will make engine repair necessary.
Note: The timing must be checked before the timing adjustments are made. Refer to "Timing Check Procedure" for the procedure.
After the Timing Check procedure is complete, the timing bolt will be engaged in the flywheel. The No. 1 piston will be at the top center (TC) position.
(2) Rocker shaft
Camshaft drive gears (RH side)|
(3) Drive gear
- Remove all the valve covers on the side for the camshaft adjustment. Loosen bolts (1) that hold rocker shafts (2) to the valve cover bases until all rocker arms are free from the injectors and the valves.
Note: The above procedure must be done before camshaft drive gear (3) is pulled off the camshaft taper.
- Remove the covers from the flywheel housing.
Illustration 5 g06053503 Camshaft drive gears (LH side)
(6) Timing ring
- Remove bolt (5) and plate (4) on the RH side.
- Remove bolt (5), plate (4), and timing ring (7) on LH side.
Illustration 6 g06053508 Storage position for timing pins
(7) Timing pin
- Install Tooling (T2) onto the camshaft gear with Tooling (T3) and Tooling (T4). Loosen drive gears (3) from the taper on the camshafts. Remove the engine turning tool and the gears.
- Remove timing pins (7) from the storage position on each side of the engine.
Illustration 7 g06053514 Installed camshaft timing pin
(7) Timing pin
- Turn the camshafts until timing pins (7) can be installed through the engine block and into the grooves (slots) in the camshafts.
- Clean the taper of the camshaft and clean the tapered bore of the camshaft gear. Use a lint free cloth that is saturated with a solvent to remove any excess oil. Clean the parts again with a lint free alcohol wipe to remove any residue. If the alcohol wipe is dirty after cleaning the parts, clean the parts again with a clean lint free alcohol wipe. Repeat the cleaning until no residue is left on the alcohol wipe.
Note: The taper of the camshaft and the tapered bore of the camshaft gear must be clean, dry, and free of residue.
- Ensure that both camshafts have the pins in place.
- Ensure that the flywheel has the pin in place.
- Install the camshaft gears onto the camshafts and remove any backlash by rotating the gears in the opposite direction of engine rotation. Use hand pressure to turn and hold the camshaft drive gears in the opposite direction of the rotation. The procedure removes all gear clearance (backlash) between the camshaft drive gears (3) and the idler gears.
- Install timing ring (6), the accessory drive gear, or plate (4) according to the assembly.
Note: Ensure that the hole in the timing ring is properly seated on the locating pin.
- Tighten the retaining bolts for the camshaft gears.
360 N·m (265 lb ft)
- Mark a vertical line on the head of the bolt for the camshaft gear. Refer to Illustration 8.
Illustration 8 g01226674 Vertical line
- Place a driver against the retaining plate of the camshaft gear. Strike the driver solidly with a hammer 3 to 4 times.
- Tighten the retaining bolts for the camshaft gears again.
360 N·m (265 lb ft) Illustration 9 g01226685
- Repeat steps 15 and 16 until the mark on the bolt turns a minimum of 90 degrees. Refer to Illustration 9.
- Install the gaskets and covers on the flywheel housing.
- Remove timing pins (6) from the camshafts. Install timing pins (6) in the storage positions. Install the covers over the camshafts and timing pins (6).
- Remove the timing bolt from the flywheel housing. Install the 8T-6765 Pipe Plug in the flywheel housing timing hole. Remove the engine turning tool. Install the cover and the gasket.
- Be certain that the rocker arms are correctly engaged with the pushrods. Tighten the bolts to hold all the rocker shafts in position.
- Adjust the valves and the lash of the electronic fuel injector.