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001-088 Engine Base Timing

General Information

Front Gear Assembly Configuration

Two front gear train combinations are currently utilized on the Signature, ISX, and QSX15
engines. Signature, ISX3, ISX2 and QSX15 use a scissor gear for the lower idler gear and the
injector cam gear. ISX1 does not use a scissor gear at the idler location.

ISX2 engine built between January, 1999 and January, 2000 utilized a scissor gear for the lower
idler gear only. The injector cam gear was a straight cut spur gear similar to the ISX1. After
January, 2000, the ISX2 contains scissor gears for both the cam and lower idler.

This procedure describes the removal, inspection, and installation of all the different gear
combinations.

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Front Gear Assembly without Scissor Gear

View shown is from left to right and top to bottom.

 Valve camshaft gear

 Injector camshaft gear
 Adjustable idler gear
 Lower idler gear
 Accessory gear
 Crankshaft gear.

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Front Gear Assembly with Scissor Gear

View shown is from left to right and top to bottom.

 Valve camshaft gear

 Injector camshaft scissor gear
 Adjustable idler gear
  Lower idler scissor gear
 Accessory gear
 Crankshaft gear.

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Scissor Gear Definitions

WARNING

Do not attempt to remove any gears before reading scissor gear definitions. Serious
personal injury or engine damage can result if instructions are not followed.

The following terms describe the conditions of the scissor gears for removal, installation, and
operation.
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Unloaded:

The gear will be unloaded when removing, installing, and setting gear backlash.

Unload the gear by backing out two gear adjusting screws until the gear teeth align.

The idler scissor gear is loaded when the gear backlash is set.
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Loaded:

The gear teeth are loaded (functional) and are spread between the mating gear teeth.

The gear is loaded by tightening all of the adjusting screws. The gear teeth will be spread and no
movement will be felt against the valve cam gear. The gear will be in the loaded condition for
engine operation.
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Preparatory Steps

All Applications

QSX15 engines are equipped with dual vibration dampers. The crank pin mark is located on the
damper closest to the engine.

Rotate crankshaft clockwise until the ”insert pin” mark on the outside diameter of engine
vibration damper is aligned with the mark on the gear housing.
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Insert the pin in the hole in the pin boss.

The green band on the timing pin will be lined up with the surface of the timing pin boss of the
block.

The pin is not correctly seated in the crank notch if the green band is either completely visible
outside the block, or is not visible at all.

Lock the crankshaft in place with the crankshaft locking pin, Part Number 3163020.
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Remove the rocker lever cover and gasket. Refer to Procedure 003-011.
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Disconnect and remove the engine brake wiring harness. Refer to Procedure 020-015.
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Removing the rocker lever shafts removes the load from the camshafts. This allows the
camshafts to be rotated when installing the timing wedges and the camshaft gears are not
installed.

Remove the rocker lever shafts. Refer to Procedure 003-009.

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Removal of the lower front cover is not required when setting the gear backlash on engines that
utilize all non-scissor gears. An access hole is provided to insert a shim between the lower non-
scissor idler gear and the adjustable idler gear. The access hole is sealed with a plug.

It will be helpful to push the gear cover plug out from the rear. It is not necessary to remove the
lower gear cover to push out the plug.
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Remove the upper gear cover. Refer to Procedure 001-079.

Remove the lower gear cover, if needed. Refer to Procedure 001-080.

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Remove

Valve Camshaft Gear

The injector camshaft scissor gear must be unloaded during removal of the valve camshaft gear.
To unload the gear, two of the gear screws must be backed out far enough to allow the teeth on
the scissor gear to be aligned.

Unload the injector camshaft scissor gear.

Remove the valve camshaft gear mounting capscrew and washer.

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Early production engines were not equipped with puller holes in the valve camshaft gear. A 3-
jaw gear puller must be used for gears that do not have puller holes. The injector and valve gear
puller, Part Number 3163069, can be used for gears that have puller holes.

Install the gear puller, Part Number 3163069.

Install the valve camshaft gear mounting capscrew completely.

Loosen the capscrew two turns.

Using the gear puller, remove the valve camshaft gear from the camshaft nose.
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Remove the puller.

Do not completely remove the camshaft gear mounting capscrew when the 3-jaw puller is used.
The capscrew serves as a safety catch by preventing the gear from shooting off of the camshaft
nose.

Remove the valve camshaft gear mounting capscrew, valve camshaft gear.
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Injector Camshaft Scissor Gear

CAUTION

Remove the rear injector camshaft cover plate before removal of the injector camshaft
gear or camshaft. The force required to remove the camshaft gear creates sufficient
backwards movement of the camshaft to crack the rear cover plate.

Remove the injector camshaft rear cover plate.

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Remove the injector camshaft scissor gear mounting capscrew and washer.

Install gear puller, Part Number 3163069.

Install the injector camshaft scissor gear mounting capscrew. Loosen the capscrew one turn.
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Using the gear puller, force the injector camshaft scissor gear off the camshaft taper.

Remove the gear puller.

Remove the capscrew.

Remove the injector camshaft scissor gear.

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Injector Camshaft Non-Scissor Gear

CAUTION

Remove the rear injector camshaft cover plate before removal of the injector camshaft
gear or camshaft. The force required to remove the camshaft gear creates sufficient
backwards movement of the camshaft to crack the rear cover plate.

Remove the injector camshaft rear cover plate.

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Remove the injector camshaft gear mounting capscrew and washer.

Install gear puller, Part Number 3163069.

Install the injector camshaft gear mounting capscrew. Loosen the capscrew one turn.
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Using the gear puller, force the injector camshaft gear off the camshaft taper.

Remove the gear puller.

Remove the capscrew.

Remove the injector camshaft gear.

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Adjustable Idler Gear

The adjustable idler gear shaft can fall out when the adjustable idler gear is removed.

Remove the retainer capscrews, retainer, gear, and adjustable idler gear shaft.
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Remove the mounting spacer.

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Lower Idler Scissor Gear

The lower idler scissor gear must be unloaded during removal. To unload the gear, two of the
gear screws must be backed out far enough to allow the teeth on the scissor gear to be aligned.

Unload the lower idler scissor gear.

Remove one lower idler scissor gear capscrew and install the guide stud.
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Remove the remaining capscrews.

Remove the retainer, gear, shaft, and thrust bearing.

Remove the guide stud.

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Lower Idler Non-Scissor Gear

Remove one lower idler non-scissor gear capscrew and install the guide stud.
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Remove the remaining capscrews.

Remove the retainer, gear, shaft, and thrust bearing.

Remove the guide stud.

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Inspect for Reuse

Inspect the gear teeth on all gears for pitting, heavy wear, or breakage. Replace the suspect gear
and inspect the mating gear for resulting damage.
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Inspect the lower idler shaft and adjustable idler shaft for heavy wear.

Measure the idler shafts outside diameter.

mm in
88.88 MIN 3.4992
88.89 MAX 3.4997

mm in
88.88 MIN 3.4992
88.89 MAX 3.4997
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Inspect the lower idler gear bore and adjustable idler gear bore for heavy wear.

Measure the inside diameter of the lower idler and adjustable idler gear bores.

mm in
88.962 MIN 3.5024
88.988 MAX 3.5035

mm in
88.962 MIN 3.5024
88.988 MAX 3.5035
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Install

Timing Wedges:

The timing code is located on the engine dataplate.

 First number - injector wedge

 Second number - valve wedge.
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Make sure the wedges with the proper angles are used and that the wedges are properly seated in
their installed position.

Insert the correct timing wedge to lock the injector camshaft. Lightly tap the top of the timing
wedge with a mallet to be sure it is properly seated.
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WARNING

Do not drive the wedges into place. Engine damage can occur.

Make sure the wedges with the proper angles are used and that the wedges are properly seated in
their installed position.

Insert the correct timing wedge to lock the valve camshaft. Lightly tap the top of the timing
wedge with a mallet to be sure it is properly seated.
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Lower Idler Scissor Gear

Install the guide stud.

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The lower scissor idler gear must be unloaded during installation. To unload the gear, two of the
gear screws must be backed out far enough to allow the teeth on the scissor gear to be aligned.

Apply Lubriplate™ to the thrust bearing, shaft, and lower scissor idler gear.

Install the thrust bearing, shaft, and lower scissor idler gear. The shaft must be installed with the
word “TOP” (stamped on the end of the shaft) toward the top of the engine.
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The lower idler scissor gear front retainer plate is larger in diameter than the adjustable idler
retainer plate. The slots in the plate go toward the scissor gear

Install the retainer and capscrews. Remove the guide stud.

Install the remaining capscrew and tighten all capscrews in a star pattern.

Torque Value: Step 1 30 n.m [22 ft-lb]

Step 2 Rotate each capscrew an additional 60 degrees in the same sequence as above.
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CAUTION

Make sure all the scissor gear screws are tightened to the proper torque so that they do not
back out during engine operation. Serious engine damage can occur.

Load the lower idler scissor gear by tightening all the gear screws.

Torque Value: 28 n•m [ 21 ft-lb ]

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Lower Idler Non-Scissor Gear

Install the guide stud.

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Apply Lubriplate™ to the thrust bearing, shaft, and lower non-scissor idler gear.

Install the thrust bearing, shaft, and lower non-scissor idler gear. The shaft must be installed with
the word “TOP” (stamped on the end of the shaft) toward the top of the engine.
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The lower idler non-scissor gear front retainer plate is larger in diameter than the adjustable idler
retainer plate. The slots in the plate go toward the scissor gear

Install the retainer and capscrews. Remove the guide stud.

Install the remaining capscrew and tighten all capscrews in a star pattern.

Torque Value: Step 1 30 n.m [22 ft-lb]

Step 2 Rotate each capscrew an additional 60 degrees in the same sequence as above.
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Adjustable Idler Gear

The spacer plate is doweled to the block with two standard dowels.

Install the mounting spacer plate.

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Apply Lubriplate™ to the spacer, shaft, and adjustable idler gear.

It is possible to install the shaft in a different orientation, however it will not be possible to set
the gear backlash correctly.

Install spacer, shaft and adjustable idler gear. The shaft must be installed with the word “TOP”
(stamped on the front face of the shaft) oriented toward the top of the engine.
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The adjustable idler front retainer plate is smaller in diameter than the lower idler scissor gear
retainer plate. The slots on the retainer plate go toward the gear.

The adjustable idler gear is installed loosely because it is moved into its final position later in the
timing process.

Install the retainer and capscrews. Finger-tighten the capscrews and then loosen by one “flat,”
which is 60 degrees.
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Injector Camshaft Scissor Gear

Install the injector camshaft rear cover plate.

Torque Value: 40 n•m [ 30 ft-lb ]

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CAUTION

The injector camshaft nose and injector camshaft scissor gear must be clean and dry prior
to assembly. Wipe off the taper surface with a lint-free cloth and do not touch the surfaces
after wiping. Engine damage can occur.

The injector camshaft scissor gear must be unloaded during installation. To unload the gear, two
of the gear screws must be backed out far enough to allow the teeth on the scissor gear to be
aligned.
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The injector camshaft scissor gear needs to be fully engaged on the camshaft nose taper, yet
loose enough so that it can rotate on the camshaft nose.

Install injector camshaft scissor gear loosely on camshaft nose taper.

The injector camshaft scissor gear mounting washer is larger in diameter than the valve camshaft
mounting washer.

Install the mounting washer and capscrew.

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Finger-tighten the capscrew and then loosen by one “flat,” which is 60 degrees.

The injector camshaft scissor gear is still loose at this point to allow the adjustable idler gear to
be properly positioned.

Do not seat the gear.

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Injector Camshaft Non-Scissor Gear

Install the injector camshaft rear cover plate.

Torque Value: 40 n•m [ 30 ft-lb ]

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CAUTION

The injector camshaft nose and injector camshaft non-scissor gear must be clean and dry
prior to assembly. Wipe off the taper surface with a lint-free cloth and do not touch the
surfaces after wiping. Engine damage can occur.
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The injector camshaft non-scissor gear needs to be fully engaged on the camshaft nose taper, yet
loose enough so it can rotate on the camshaft nose.

Install injector camshaft non-scissor gear loosely on camshaft nose taper.

The injector camshaft non-scissor gear mounting washer is larger in diameter than the valve
camshaft mounting washer.

Install the mounting washer and capscrew.

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Finger-tighten the capscrew and then loosen by one “flat,” which is 60 degrees.

The injector camshaft non-scissor gear is still loose at this point to allow the adjustable idler gear
to be properly positioned.

Do not seat the gear.

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Valve Camshaft Gear

CAUTION

The valve camshaft nose and valve camshaft gear must be clean and dry prior to assembly.
Wipe off the shaft surface and gear with a lint-free cloth and do not touch the surfaces
after wiping. Engine damage can occur.
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The valve camshaft gear needs to be fully engaged on the camshaft nose taper, yet loose enough
so that can rotate on the camshaft nose.

Install the valve camshaft gear loosely on the camshaft nose taper.

The valve camshaft mounting washer is smaller in diameter than the injector camshaft scissor
gear mounting washer.

Install the mounting washer and capscrew.

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Finger-tighten the capscrew and then loosen by one “flat,” which is 60 degrees.

The valve camshaft gear is still loose at this point to allow the adjustable idler gear to be properly
positioned.

Do not seat the gear.

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Adjust

Backlash (Non Gear Combinations)

WARNING

Do not set backlash between the adjustable idler gear and the lower scissor idler gear.
Serious engine damage can occur.

This backlash step works with the scissor type injector camshaft gear and lower idler gear, and
the non-scissor injector camshaft gear with a scissor type lower idler gear.

The injector camshaft scissor gear must still be unloaded during this step. To unload the gear,
two of the gear screws must be backed out far enough to allow the teeth on the scissor gear to be
aligned.
Insert, as shown, a narrow shim (0.25 mm [0.010 in]) into the gear teeth mesh between the
adjustable idler gear and the wide (rear side) gear of the injector camshaft scissor gear.

mm in
0.225 MIN 0.009
0.275 MAX 0.011

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Note : The gear backlash set procedure for engines that have a non-scissor injector
camshaft gear and a scissor type lower idler gear is the same as that of engine that utilize
two scissor type gears.

Using hand pressure only, move the adjustable idler gear toward the center of the engine (into
mesh) so there is no gap between on either side of the shim.

Both of the camshaft gears will rotate slightly on the camshafts during this step.

Slight drag will be felt on the shim while pulling the shim in and out.
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Backlash (Non-Scissor Gear Combinations)

Removal of the lower front cover is not required when setting the gear backlash on engines that
utilize all non-scissor gears. An access hole is provided to insert a shim between the lower non-
scissor idler gear and the adjustable idler gear. The access hole is sealed with a plug. The plug
can be pushed out from the rear side without removing the gear cover.

The following procedure will be shown with the lower gear cover removed.
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Insert, as shown, a shim (0.25 mm [0.010 in]) into the gear teeth mesh between the adjustable
idler gear and the injector camshaft gear. The shim is inserted on the load side of the gear teeth.

Insert, as shown, a shim (0.25 mm [0.010 in]) into the gear teeth mesh between the adjustable
idler and the lower non-scissor idler gear. The shim is inserted on the load side of the gear teeth.

Using hand pressure only, move the adjustable idler gear so there is no gap between the teeth and
either side of the shims.

Both of the camshaft gears will rotate slightly on the camshafts during this step.

Slight drag will be felt on the shim while pulling the shim in and out.
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Adjustable Idler Gear

While holding the adjustable idler gear in position, tighten the adjustable idler gear mounting
capscrews.

Torque Value: Step 1 30 n.m [22 ft-lb]

Step 2 Rotate each capscrew an additional 60 degrees in the same sequence as above.

Remove the feeler gauge.

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Injector Camshaft Scissor Gear

CAUTION

Make sure all the scissor gear screws are tightened to the proper torque so that they do not
back out during engine operation. Severe engine damage can occur.

Load the injector camshaft scissor gear by tightening all the gear screws.

Torque Value: 28 n•m [ 21 ft-lb ]

The valve camshaft gear will rotate slightly on the valve camshaft during this step.
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Tighten the injector camshaft scissor gear retaining capscrew.

Torque Value: Step 1 216 n.m [160 ft-lb]

Step 2 Rotate 90 degrees
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Injector Camshaft Non-Scissor Gear

Use hand pressure only to rotate the injector camshaft gear clockwise until the gear train
backlash is taken up. Obtain tooth-to-tooth contact between the crankshaft gear and the injector
camshaft gear.
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Tighten the injector camshaft non-scissor gear retaining capscrew.

Torque Value: Step 1 218 n.m [161 ft-lb]

Step 2 Rotate 90 degrees.
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Valve Camshaft Scissor Gear

Tighten the valve camshaft scissor gear retaining capscrew.

Torque Value: 148 n•m [ 109 ft-lb ]

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Valve Camshaft Non-Scissor Gear

Use hand pressure only to rotate the valve camshaft gear counterclockwise until the backlash
between the injector camshaft gear is taken up. Obtain tooth-to-tooth contact between the
injector camshaft gear and the valve camshaft gear.
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Tighten the valve camshaft non-scissor gear retaining capscrew.

Torque Value: 148 n•m [ 109 ft-lb ]

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Coat the entire gear train with clean 15W-40 oil.

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Use the access hole in the lower gear cover to lubricate the lower idler gear and crankshaft.
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Finishing Steps

All Applications

Remove the injector and valve camshaft timing wedges.

A sudden jerking motion upwards is the most effective way to remove wedges.
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Remove the crankshaft locking pin.

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Install the upper gear cover. Refer to Procedure 001-079.

Install the lower gear cover. Refer to Procedure 001-080.

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Install the rocker lever shafts. Refer to Procedure 003-009.

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Install and connect the engine brake wiring harness. Refer to Procedure 020-015.
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Install the rocker lever cover and gasket. Refer to Procedure 003-011.
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Last Modified: 16-Jun-2006

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