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

Installation Procedure (Standard Idler Gear)

1. Ensure that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center for No. 1 Piston" for the correct procedure.
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   Illustration 1	g01337918
   Alignment of timing marks

2. Ensure that Tooling (A) is installed into Hole (X) in camshaft gear (1).
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   Illustration 2	g01337947

3. 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. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.
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   Illustration 3	g01337949

4. Clean idler gear (2) and inspect the idler gear for wear or damage. Refer to Specifications, "Gear Group (Front)" for more information. If necessary, replace the idler gear.

5. Clean hub (7) and inspect the hub for wear or damage. Refer to Specifications, "Gear Group (Front)" for more information. If necessary, replace the hub.

6. Lubricate hub (7) with clean engine oil. Slide hub (7) into idler gear (2). Ensure that the timing marks are toward the front of the idler gear.
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   Illustration 4	g01337952

7. Align the timing mark on idler gear (2) with the timing mark on the camshaft gear. Refer to the illustration 1. Install the assembly of idler gear (2) and hub (7) into the recess in the timing case. Ensure that oil Hole (Z) is to the top of the hub.

   Note: The idler gear must be tilted during installation. Ensure that the holes in the hub are aligned with the holes in the cylinder block.

8. Clean plate (3) and inspect the plate for wear or damage. If necessary, replace the plate.

9. Lubricate plate (3) with clean engine oil. Align the holes in plate (3) with the holes in hub (7). Install the plate in the original orientation.

10. Install bolts (1).

11. Remove Tooling (A) and Tooling (B).

    Note: Ensure that timing marks are aligned, before removing the Tooling (A) and Tooling (B).

12. Install plug (8) to the cylinder block. Refer to Illustration 2.

13. Tighten bolts (1) to a torque of 44 N·m (32 lb ft).
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    Illustration 5	g01337953
    Checking end play by using a set of feeler gauge's

14. Use a set of feeler gauge's in order to check the end play for the idler gear. Refer to Specifications, "Gear Group (Front)" for more information.
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    Illustration 6	g01335426
    Checking backlash

15. Check the backlash between the idler gear and the camshaft gear. Refer to Specifications, "Gear Group (Front)" for more information.

16. Check the backlash between the idler gear and the crankshaft gear. Refer to Specifications, "Gear Group (Front)" for more information.

17. Lightly lubricate all of the gears with clean engine oil.

End By:

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

Installation Procedure (Early Heavy-Duty Idler Gear)

1. Ensure that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center for No. 1 Piston" for the correct procedure.
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   Illustration 7	g01337924
   Alignment of timing marks

2. Ensure that Tooling (A) is installed into Hole (X) in the camshaft gear.
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   Illustration 8	g01337954

3. 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. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.

4. Clean the assembly of idler gear (2) and inspect the assembly of the idler gear for wear or damage. Refer to Specifications , "Gear Group (Front)" for more information. If necessary, replace the assembly of the idler gear.

5. Lubricate the bearings in the assembly of idler gear (2) with clean engine oil.
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   Illustration 9	g01337922

6. Align the timing mark on idler gear (2) with the timing mark on the camshaft gear. Refer to the illustration 7. Install the assembly of idler gear (2) into the recess in the timing case. Ensure that the identification mark TOP is upward.

   Note: The idler gear must be tilted during installation. Ensure that the holes in assembly of the idler gear are aligned with the holes in the cylinder block.

7. Install bolts (1).

8. Remove Tooling (A) and Tooling (B).

   Note: Ensure that timing marks are aligned, before removing the Tooling (A) and Tooling (B).

9. Install plug (6) to the cylinder block. Refer to Illustration 8.

10. Tighten bolts (1) to a torque of 44 N·m (32 lb ft).
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    Illustration 10	g01337957

11. Use Tooling (C) in order to check the end play for the heavy-duty idler gear. Refer to Specifications, "Gear Group (Front)" for more information.
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    Illustration 11	g01335426
    Checking backlash

12. Check the backlash between the idler gear and the camshaft gear. Refer to Specifications, "Gear Group (Front)" for more information.

13. Check the backlash between the idler gear and the crankshaft gear. Refer to Specifications, "Gear Group (Front)" for more information.

14. Lightly lubricate all of the gears with clean engine oil.

End By:

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

Installation Procedure (Latest Heavy-Duty Idler Gear)

1. Ensure that number one piston is at the top center Position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Finding Top Center Postion for No. 1 Piston" for the correct procedure.
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   Illustration 12	g01343977
   Alignment of timing marks

2. Ensure that Tooling (A) is installed into Hole (X) in the camshaft gear.

3. 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. Refer to Systems Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.
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   Illustration 13	g01387344
   Typical example

4. Install plate (6) into the recess in the front housing.

   Note: Ensure that the identification mark TOP is upward.

5. Clean the assembly of idler gear (2) and inspect the assembly of the idler gear for wear or damage. Refer to Specifications, "Gear Group (Front)" for more information. If necessary, replace the assembly of the idler gear.

6. Lubricate the bearings in the assembly of idler gear (2) with clean engine oil.
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   Illustration 14	g01269933

7. Align the timing mark on idler gear (2) with the timing mark on the camshaft gear. Refer to Illustration 12. Install the assembly of idler gear (2) into the recess in the timing case. Ensure that the identification mark TOP is upward.

   Note: The idler gear must be tilted during installation. Ensure that the holes in the assembly of the idler gear are aligned with the holes in the cylinder block.

8. Install bolts (1). Tighten bolts (1) to a torque of 44 N·m (32 lb ft).
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   Illustration 15	g01269937
   Checking end play by using a dial indicator group

9. Use Tooling (C) in order to check the end play of the idler gear. Refer to Specifications, "Gear Group (Front)" for more information.

10. Use Tooling (C) in order to check the backlash between the idler gear and the camshaft gear. Refer to Specifications, "Gear Group (Front)" for more information.

11. Use Tooling (C) in order to check the backlash between the idler gear and the crankshaft gear. Refer to Specifications, "Gear Group (Front)" for more information.

12. Lightly lubricate all of the gears with clean engine oil.

End By:

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

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

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