C6.6 Engines for Caterpillar Built Machines Idler Gear - Remove Caterpillar


Idler Gear - Remove
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1.1. Removal Procedure (Standard Idler Gear)
2.1. Removal Procedure (Early Heavy-Duty Idler Gear)
3.1. Removal Procedure (Latest Heavy-Duty Idler Gear)

Removal Procedure (Standard Idler Gear)

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
230-6284  Timing Pin (Camshaft) 
136-4632  Timing Pin (Crankshaft) 
268-1966 Adapter 

Start By:

  1. Remove the fuel injection pump gear. Refer to Disassembly and Assembly, "Fuel Pump Gear - Remove" for the correct procedure.

  2. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure.

Note: Care must be taken in order to ensure that the fuel injection pump timing is not lost during the removal of the fuel pump gear. Carefully follow the procedure in order to remove the fuel pump gear.


NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.




    Illustration 1g01337918
    Alignment of timing marks

  1. Ensure that Tooling (A) is installed into Hole (X) in the camshaft gear. Use Tooling (A) in order to lock the camshaft in the correct position.

    Note: Ensure that the gears are marked in order to show alignment. Refer to Illustration 1.



    Illustration 2g01337919

  2. Ensure that Tooling (B) is installed in Hole (Y) in the cylinder block. Use Tooling (B) in order to lock the crankshaft in the correct position.


    Illustration 3g01337921

  3. Loosen nuts (5) on all rocker arms (6). Unscrew adjusters (4) on all rocker arms (6) until all valves are fully closed.

    Note: Failure to ensure that ALL adjusters are fully unscrewed can result in contact between the valves and pistons.

  4. Mark plate (3) in order to show orientation.

    Note: Identification will ensure that the plate can be installed in the original orientation.

  5. Remove bolts (1).

  6. Remove plate (3).


    Illustration 4g01337922

  7. Remove the assembly of idler gear (2) and hub (7) from the recess in the front housing.

    Note: The idler gear must be tilted during removal.

  8. Remove hub (7) from idler gear (2).

Removal Procedure (Early Heavy-Duty Idler Gear)

Table 2
Required Tools 
Tool  Part Number  Part Description  Qty 
230-6284  Timing Pin (Camshaft) 
136-4632  Timing Pin (Crankshaft) 
268-1966 Adapter 

Start By:

  1. Remove the fuel injection pump gear. Refer to Disassembly and Assembly, "Fuel Pump Gear - Remove" for the correct procedure.

  2. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure.

Note: Care must be taken in order to ensure that the fuel injection pump timing is not lost during the removal of the fuel pump gear. Carefully follow the procedure in order to remove the fuel pump gear.


NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.


Note: The assembly of heavy-duty idler gear is not serviceable. Do not disassemble the heavy-duty idler gear.



    Illustration 5g01337924
    Alignment of timing marks

  1. Ensure that Tooling (A) is installed into hole (X) in the camshaft gear. Use Tooling (A) in order to lock the camshaft in the correct position.

    Note: Ensure that the gears are marked in order to show alignment. Refer to Illustration 5.



    Illustration 6g01337919

  2. Ensure that Tooling (B) is installed in hole (Y) in the cylinder block. Use Tooling (B) in order to lock the crankshaft in the correct position.


    Illustration 7g01337921

  3. Loosen nuts (4) on all rocker arms (5). Unscrew adjusters (3) on all rocker arms (5) until all valves are fully closed.

    Note: Failure to ensure that ALL adjusters are fully unscrewed can result in contact between the valves and pistons.

  4. Remove bolts (1) from the assembly of heavy-duty idler gear (2).


    Illustration 8g01337922

  5. Remove the assembly of idler gear (2) from the recess in the front housing.

    Note: The idler gear must be tilted during removal.

Removal Procedure (Latest Heavy-Duty Idler Gear)

Table 3
Required Tools 
Tool  Part Number  Part Description  Qty 
230-6284  Timing Pin (Camshaft) 
136-4632  Timing Pin (Crankshaft) 
268-1966 Adapter 
Bolt
(M8 x 80mm) 

Start By:

  1. If the engine is equipped with an air compressor, remove the air compressor. Refer to Disassembly and Assembly, "Air Compressor - Remove and Install" for the correct procedure.

  2. If the engine is equipped with an accessory drive, remove the accessory drive. Refer to Disassembly and Assembly, "Accessory Drive - Remove and Install" for the correct procedure.

  3. Remove the fuel injection pump gear. Refer to Disassembly and Assembly, "Fuel Pump Gear - Remove" for the correct procedure.

  4. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure.

Note: Care must be taken in order to ensure that the fuel injection pump timing is not lost during the removal of the fuel pump gear. Carefully follow the procedure in order to remove the fuel pump gear.


NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.


Note: The assembly of heavy-duty idler gear is not serviceable. Do not disassemble the heavy-duty idler gear.



    Illustration 9g01343977
    Alignment of timing marks

  1. Ensure that Tooling (A) is installed into Hole (X) in the camshaft gear. Use Tooling (A) in order to lock the camshaft in the correct position.

    Note: Ensure that the gears are marked in order to show alignment. Refer to Illustration 9.

  2. Ensure that Tooling (B) is installed in Hole (Y) in the front housing. Use Tooling (B) in order to lock the crankshaft in the correct position.


    Illustration 10g01337921
    Typical example

  3. Loosen nuts (5) on all rocker arms (6). Unscrew adjusters (4) on all rocker arms (5) until all valves are fully closed.

    Note: Failure to ensure that ALL adjusters are fully unscrewed can result in contact between the valves and pistons.

  4. Remove bolts (1) from the assembly of heavy-duty idler gear (2). Refer to Illustration 9.


    Illustration 11g01269933
    Typical example

  5. Remove the assembly of idler gear (2) from the recess in the front housing.

    Note: The idler gear must be tilted during removal.



    Illustration 12g01348835
    Typical example

  6. If necessary, remove plate (6). Install Tooling (C) into threaded Hole (Z) in order to remove plate (6).

Information System:

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C6.6 Engines for Caterpillar Built Machines Crankcase Breather - Install - Unfiltered Breather
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