COMPLETE ENGINE OVERHAUL SERIAL NO. 36J149 TO 36J560 INCLUSIVE 2P0760 - Caterpillar

Illustration 2 g00992812
Remove nut (3) and the washer from the shaft of the fuel injection pump.
Install Tooling (D) and remove fuel injection pump gear (4). Note: Do Not pry the fuel injection pump gear from the shaft of the fuel injection pump.
Remove bolts (7) and retaining plate (6).
Illustration 3 g00992822
Remove idler gear (5) and idler gear hub (9).
Use Tooling (E) and remove bushings (8) from each side of the idler gear. Installation Procedure
Table 2
A 9U-6198 Crankshaft Turning Tool 1
B 230-6284 Timing Pin (Camshaft) 1
C 230-6283 Timing Pin (Crankshaft) 1
E 1P-0510 Driver Group 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Use Tooling (A) to ensure that the No. 1 cylinder is at the top center compression stroke. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston". Note: Install Tooling (B) through the camshaft gear. Install Tooling (C) into the crankshaft web.
The valve timing and the fuel injection pump timing will be lost if the crankshaft is rotated when the idler gear is removed.
Illustration 4 g00943872
Position idler gear hub (9) and install bolts (7) in order to locate the idler gear hub. Tighten the bolts in order to seat the idler gear hub. Note: The Lubrication Hole (X) of the idler gear hub must be positioned at the top of the idler gear hub.
Use a suitable press and Tooling (E) to install bushings (8) on each side of idler gear (5).
Remove bolts (7) from the idler gear hub. Install idler gear (5) on idler gear hub (9). Note: When you install the idler gear, ensure that the marked teeth are facing toward the front.
Install retainer plate (6) and bolts (7). Tighten the bolts to a torque of 44 N m (32 lb ft).
Illustration 5 g00944081
Check the end play for the idler gear. The end play for the idler gear is 0.10 to 0.20 mm (0.004 to 0.008 inch).
Illustration 6 g00944084
Check the backlash between the idler gear and the camshaft gear. The backlash for the gears is 0.052 to 0.107 mm (0.0020 to 0.0042 inch).
Check the backlash between the idler gear and the crankshaft gear. The backlash for the gears is 0.064 to 0.124 mm (0.0025 to 0.0049 inch).
Illustration 7 g00992853Note: Ensure that the mating surfaces of the fuel injection pump gear and the shaft of the fuel injection pump are clean. Lubricate the threads of the shaft for the fuel injection pump. The nut must turn freely until contact is made with the fuel injection pump gear.
Position fuel injection pump gear (4) on the shaft of the fuel injection pump. Rotate the fuel injection pump gear in a counterclockwise direction in order to remove the backlash. Install the washer and nut (3). Tighten the nut to a torque of 24 N m (17 lb ft).
Illustration 8 g00992803
Loosen bolt (1). Move spacer (2) in order to prevent bolt (1) from tightening against the shaft of the fuel injection pump. Tighten bolt (1) to a torque of 12 N m (106