CYLINDER ASSEM. 9J2402 - Caterpillar

Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
B 1P-0510 Driver Group 1
C 8T-5096 Dial Indicator 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g03743336
Place thrust washer (5) in position on the dowels in the front housing. The thickness of the new thrust washer is 9.45 0.05 mm (0.372 0.002 inch).
Illustration 2 g01296368Note: The idler bearing in the illustration shows a groove for an internal oil supply. The new idler bearings do not have a groove for an internal oil supply.
If bearing (4) was removed, use Tooling (B) in order to install the bearing in idler gear (1). Install the bearing until Dimension (X) is 2.5 0.5 mm (0.098 0.020 inch). The inside diameter of the bearing should be 69.950 0.010 mm (2.75390 0.00040 inch) after installation.
Illustration 3 g00561404
Install O-ring seals (3) on idler shaft (2). Apply clean engine oil to the O-ring seals.
Illustration 4 g03743334Note: The idler gears on each side are different. The idler gears must be installed on the correct side in order to get the correct engagement with the crankshaft gear. The left side idler gear has 67 teeth and the right side idler gear has 68 teeth.
Apply clean engine oil to the bearing in idler gear (1).
Place idler gear (1) in position with the large shoulder of the idler gear in front. Install idler shaft (2).
The idler shafts used in the front gear group must be positioned in order to allow proper lubrication of the idler gear bearing. The idler gear contains a central pressurized oil feed hole. A cross drilled hole in the idler shaft supplies pressurized oil to the idler gear bearing.
Note: For "Standard Rotation" engines, use the Illustration that follows.
Illustration 5 g01296492
(A) Cross-drilled Oil Hole on the right side idler shaft
(B) Cross-drilled Oil Hole on the left side idler shaft
The right side idler shaft should have Oil Hole (A) in the idler shaft at the 2 O'clock position.
The left side idler shaft should have Oil Hole (B) in the idler shaft at the 5 O'clock position. Note: For "Reverse Rotation" engines, use the Illustration that follows.
Illustration 6 g01296495
(C) Cross-drilled Oil Hole on the right side idler shaft
(D) Cross-drilled Oil Hole on the left side idler shaft
The right side idler shaft should have Oil Hole (C) in the idler shaft at the 8 O'clock position.
The left side idler shaft should have Oil Hole (D) in the idler shaft at the 11 O'clock position.
Install the bolts that hold the idler shafts in place.
Use Tooling (C) in order to check the backlash between the crankshaft gear and the idler gear. The backlash should be 0.051 to 0.533 mm (0.0020 to 0.0209 inch).
Use Tooling (C) in order to check the end play of the idler gear. The end play should be 0.25 to 0.85 mm (0.010 to 0.0330 inch). End By:
Install the engine oil pump.
Install the water pumps.