FK611386 Force DECAL, CHARGER

Table 1
Required Tools
Tool Part Number Part Description Qty
A 9U-7336 Housing 1
5P-7305 Engine Turning Tool 1
B 230-6284 Timing Pin
(Camshaft) 1
C 364-9107 Timing Pin
(Fuel Injection Pump) 1
D 136-4632 Timing Pin
(Crankshaft) 1
268-1966 Adapter 1 Start By:
Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure.
Remove the rocker shaft. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod Cover - Remove" for the correct procedure.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Note: Care must be taken to ensure that the fuel injection pump timing is not lost during the removal of the front gear group. Carefully follow the procedure to remove the gear group.
If the air compressor is equipped with a hydraulic pump, remove the hydraulic pump. Refer to Original Equipment Manufactures (OEM) for the correct procedure.
If the engine is equipped with an air compressor, remove the air compressor. Refer to Disassembly and Assembly, "Air Compressor - Remove" for the correct procedure.
If the engine is equipped with only a hydraulic pump, remove the hydraulic pump. Refer to OEM for the correct procedure.
Use Tooling (A) to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.Note: Do not use excessive force to install Tooling (D). Do not use Tooling (D) to hold the crankshaft during repairs.
Illustration 1 g02486477
Remove plug (1) from the cylinder block. Remove O-ring seal (2) from the plug.
Use Tooling (A) to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure. Install Tooling (D) through Hole (W) to lock the crankshaft so that number one piston is at top dead center on the compression stroke.
Remove Tooling (D).
Illustration 2 g06460204
Install Tooling (B) through Hole (X) in camshaft gear (3) into the front housing. Use Tooling (B) to lock the camshaft in the correct position. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.
Use Tooling (C) to lock the fuel injection pump gear in the correct position. Refer to Disassembly and Assembly, "Fuel Injection Pump - Remove" for the correct procedure.
Illustration 3 g06460206
If the right-hand side of the engine is equipped with a hydraulic pump, remove the hydraulic pump. Refer to OEM for the correct procedure.
If necessary, remove bolts (9) from plate (8). Remove plate (8) and remove O-ring seal (7).
Remove circlip (6) and remove gear assembly (10) from front housing (14).
Illustration 4 g06460207
If necessary, follow Step 13a through Step 13b to disassemble gear assembly (10).
Remove circlip (13) from gear assembly (10).
Place gear assembly (10) on a suitable support. Press bearing (12) from gear (11).
Illustration 5 g06460210
Mark gear (3), gear (14), gear (15), and gear (16) to show alignment. Refer to Illustration 5.Note: Identification will ensure that the gears can be installed in the original alignment.
Remove camshaft gear (3). Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install" for the correct procedure.
Illustration 6 g06460214
Remove bolts (21) and bolts (19).
Remove tube assembly (20) from idler gear (14) and idler gear (17).
Remove plate (22).
Remove idler gear (14) from hub (23) (not shown).
Remove idler gear (17) and idler gear hub (18) from front housing (4).
Remove hub (23) (not shown) from front housing (4).
If necessary, remove bearing (24) from front ho