F17881 Force FITTING, GREASE

Illustration 1 g01857156
Gear train
Table 1
Specifications for 342-1306 Idler As    
Callout     Part Number     Part Name     Specification Description    
2     342-1306     Idler As     Torque bolts to...................
44 N m (33 lb ft)
Width of light duty idler gear and bearing assembly is
19.95 to 20.05 mm (0.78543 to 0.78937 inch).
Width of medium duty and heavy duty idler gear and bearing assembly is
25.45 to 25.55 mm (1.00197 to 1.00590 inch).
Inside diameter of light duty idler gear bearings is
60.022 to 60.052 mm (2.36307 to 2.36425 inch).
Inside diameter of medium duty and heavy duty idler gear bearings is
56.00 to 56.03 mm (2.20472 to 2.20590 inch).
Outside diameter of light duty idler gear hub is
59.95 to 59.97 mm (2.36023 to 2.36102 inch).
Outside diameter of medium duty and heavy duty idler gear hub is
55.95 to 55.97 mm (2.20275 to 2.20354 inch).
Clearance of light duty idler gear bearing on hub is
0.052 to 0.102 mm (0.00205 to 0.00402 inch).
Clearance of medium duty and heavy duty idler gear bearing on hub is
0.03 to 0.08 mm (0.00118 to 0.00315 inch).
The end play of the light duty idler gear is
0.05 to 0.25 mm (0.00197 to 0.00984 inch).
The end play of the medium duty and heavy duty idler gear is
0.05 to 0.25 mm (0.00197 to 0.00984 inch).
Number of teeth...................97    Backlash values Backlash between the idler gear (2) and the crankshaft gear (6) ... 0.05 to 0.15 mm (0.0020 to 0.0059 inch) Backlash between the camshaft gear (1) and the idler gear (2) ... 0.05 to 0.15 mm (0.0020 to 0.0059 inch) Backlash between the fuel injection pump gear (3) and the idler gear (2) ... 0.05 to 0.15 mm (0.0020 to 0.0059 inch)Removal Procedure
Table 2
Required Tools    
Tool     Part Number     Part Description     Qty    
A     364-9107     Timing Pin (Fuel Injection Pump)     1    
B     230-6284     Timing Pin (Camshaft)     1    
C     136-4632     Timing Pin (Crankshaft)     1    
D     298-5564     T40 Torx Socket     1    Start By:
Remove the front cover. Refer to Disassembly and Assembly, "Front Cover" for the correct procedure.
Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover" 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 idler gear. Carefully follow the procedure in order to remove the fuel pump gear.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shorten component life.
Illustration 2 g01994555
Illustration 3 g01994553
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.
Remove plug (2) from the cylinder block and remove O-ring seal (1) from the plug.
Ensure that Tooling (C) is installed in Hole (Y) in the cylinder block. Use Tooling (C) in order to lock the crankshaft in the correct position.
Ensure that Tooling (B) is installed into Hole (X) in camshaft gear (3). Use Tooling (B) 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 3.
Use Tooling (A) in order to lock the fuel injection pump gear in the correct position. Refer to Disassembly and Assembly, "Fuel Injection Pump" for the correct procedure.
Illustration 4 g01994556
Use Tooling (D) in order to loosen threaded inserts (5) on all rocker arms (6). Unscrew threaded inserts (5) on all rocker arms (6) until all valves are fully closed.Note: Failure to ensure that ALL threaded inserts are fully unscrewed can result in contact between the valves and pistons.
Illustration 5 g01994576
Illustration 6 g01994557