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Idler Gear, Camshaft - Trainings

The document provides detailed instructions for the removal and installation of idler shafts and gears in engines, including safety warnings and specific measurements for components. It emphasizes the importance of correct orientation during installation to prevent malfunctions and outlines procedures for magnetic crack inspection. Additionally, it includes torque values and finishing steps to ensure proper assembly and functionality.

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Soe Htike Aung
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22 views8 pages

Idler Gear, Camshaft - Trainings

The document provides detailed instructions for the removal and installation of idler shafts and gears in engines, including safety warnings and specific measurements for components. It emphasizes the importance of correct orientation during installation to prevent malfunctions and outlines procedures for magnetic crack inspection. Additionally, it includes torque values and finishing steps to ensure proper assembly and functionality.

Uploaded by

Soe Htike Aung
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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(/qs3/pubsys2/xml/en/manual/4021499/4021499-titlepage.

html)

Trainings

Preparatory Steps
 WARNING 
This component weighs 23 kg [50 lb] or more. To reduce the
possibility of personal injury, use a hoist or get assistance to
lift this component.

Remove the front cover. Refer to Procedure 001-031 in


Section 1 (/qs3/pubsys2/xml/en/procedures/18/18-001-
031-tr.html).
Rotate the engine by turning the crankshaft until the index
marks on the crankshaft and camshaft gears are in
alignment.
Note : The marks on the crankshaft and camshaft
gears must point straight at one another. The marks on
the idler gear do not have to be aligned as long as the
crankshaft and camshaft gears are in alignment.

Remove
Bolt-On Type
The bolt-on idler shaft has a ange that requires the shaft, gear,
and thrust washers to be removed as an assembly.
Note : The shafts used in newer engines do not have
threads to be used with a puller. Loosen the capscrew
(36), but do not completely remove it.
Remove the capscrew (36).
Use an old piston pin and a K19 cylinder head capscrew as a
slide hammer (37).
Thread the capscrew into the idler shaft.

Use the slide hammer (37) to remove the shaft (38), two thrust
washers (39), and the gear as an assembly.

For shafts used in newer engines, make sure the capscrew is


threaded into the cylinder block.

Pry the gear and shaft assembly out of the cylinder block with
two pry bars.

Press-Fit Type
Some engines have a press- t design idler shaft that does not
have to be removed from the block to remove the idler gear.

Remove the capscrew, washers, gear, and thrust washer.

Install
Bolt-On Type

 CAUTION 
The oil holes in the camshaft idler shaft and hydraulic pump
idler shaft must be installed at a speci c orientation. If the
shaft is not oriented correctly, a malfunction of the gear
bushing can result.

Mark the ange of the shaft to show the oil hole orientation.

Measure the inside diameter.

Idler Gear Bushing Inside Diameter


mm in
47.638 MIN 1.8755
47.714 MAX 1.8785

Note : The bushing in the gear is precision-bored after


installation. If machining capability is not available,
replace the bushing and the gear as an assembly.

Measure the outside diameter.

Camshaft Idler Shaft Outside Diameter (1)


mm in
25.387 MIN 0.9995
25.400 MAX 1.0000

Camshaft Idler Shaft Outside Diameter (2)


mm in
47.549 MIN 1.8720
47.600 MAX 1.8740

Check the grooved side for damage.


Measure the thrust bearing thickness.

Thrust Bearing Thickness


mm in
0.235 MIN 0.092
0.245 MAX 0.096
Oversize thrust bearings are available to adjust the end
clearance.

Magnetic Crack Inspect


 CAUTION 
Use copper braid contact that has neoprene covers to avoid
burning the teeth of the gear.

 CAUTION 
If the gear contains a keyway, position the gear so that the
keyway points toward one of the contacts when checking.

Use a magnetic particle testing machine.

Use the residual method. Apply head shot amperage.


Adjust the amperage to the speci ed value.

Gear Outside Diameter Amperage DC


Less than 101 mm [4.0 in] 1000
101 to 203 mm [4.0 to 8.0 in] 1500
Greater than 203 mm [8.0 in] 2000
Check the gear for cracks.

 CAUTION 
If the gear contains a keyway, position the gear so that the
keyway points toward one of the contacts when checking.

Use a magnetic particle testing machine.


Use the residual method. Apply head shot amperage.

Adjust the amperage to the speci ed value.

Gear Outside Diameter Amperage DC


Less than 101 mm [4.0 in] 4000
101 to 203 mm [4.0 to 8.0 in] 6000
Gear Outside Diameter Amperage DC
Greater than 203 mm [8.0 in] 8000

Note : Ampere turn is an electrical current of one


ampere owing through the coil, multiplied by the
number of turns in the coil.
Check the gear for cracks.

Limits of Acceptance - Machined Surfaces


An open indication is visible to the eye after the wetting operation has been completed. An
indication below the surface is not visible to the eye after the wetting operation has been
completed. An indication below the surface can be seen with the use of ultraviolet light that is
part of the machine.

Do not use the gear if:

There is an open indication.


There is an indication below the surface that is in the shaded area as shown.
There is an indication below the surface that is longer than 6.0 mm [0.24 in].
Limits of Acceptance - Forged Surfaces

Do not use the gear if:

There is an open indication that is in a circumferential direction.


There is an open indication that is longer than 9.5 mm [0.374 in].
There is an indication below the surface that is in the shaded area.

An indication below the surface in a radial direction is acceptable (OK) in the area that is not
shaded.

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

 CAUTION 
The gear must be demagnetized completely and cleaned
thoroughly. Any small metal particles will cause engine
damage.

Demagnetize the gear.

Use solvent or steam to clean the part.

 CAUTION 
To reduce the possibility of engine damage, the grooves in
the thrust washers must be positioned toward the gear.

The timing marks on the camshaft idler gear must be visible


when the gear is installed.
Lubriplate® Number 105 multipurpose lubricant, Part Number
3163086, or equivalent.

Lubricate the capscrew with clean engine oil.


Assemble the parts as illustrated in the graphic.

 CAUTION 
Do not allow the inner thrust washer to fall between the shaft
and block or the washer will be damaged and the gear end
clearance will be too large.

The camshaft idler gear is the only gear that has timing marks.
Install the gear and shaft assembly aligning the following:
The "O" on the idler gear with the "O" on the crankshaft
gear.
The "X" on the idler gear with the "X" on the camshaft gear.

Align the camshaft idler shaft (2) so the oil drilling shaft (1) is
45 degrees clockwise from vertical as shown.
Install the capscrew and use it to pull the shaft into the bore.
Tighten the capscrew.

Torque Value:
1. 185 n•m [ 135 ft-lb ]
2. Loosen completely.
3. 60 n•m [ 45 ft-lb ]
4. Tighten 90 degrees.

Measure the camshaft idler gear end clearance.

Camshaft Idler Gear End Clearance


mm in
0.10 MIN 0.004
0.36 MAX 0.014

If the clearance is not within speci cations, check for foreign


material between the parts, or check for proper location of the
thrust washers.
Oversize thrust washers are available.

Press-Fit Type

 CAUTION 
To reduce the possibility of engine damage, the grooves in
the thrust washer must be positioned toward the gear.

Lubricate the gear bushing, shaft, and thrust washers with


Lubriplate® Number 105 multipurpose lubricant, Part Number
3163086, or equivalent.
Lubricate the capscrews with clean engine oil.

Assemble the parts as illustrated in the graphic.


Torque Value: 45 n•m [ 33 ft-lb ]

Finishing Steps
 WARNING 
This component weighs 23 kg [50 lb] or more. To reduce the
possibility of personal injury, use a hoist or get assistance to
lift this component.

Install the front gear cover. Refer to Procedure 001-031 in


Section 1 (/qs3/pubsys2/xml/en/procedures/18/18-001-
031-tr.html).

Last Modi ed: 10-Mar-2023

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