WASHER 2K4160 - Caterpillar

Remove Front Timing Gear Cover
preparatory steps: a) remove oil panb) remove water pumpc) remove vibration damper and pulley 1. Remove the vent line (1) from oil cooler inlet pipe to cylinder block.2. Remove oil cooler inlet pipes (2).3. Remove the fuel filter drain line (3).4. Disconnect the turbocharger lubrication line from front timing gear cover.5. Remove the aftercooler water pump retaining bolts or plate depending on how the engine is equipped.6. Remove the front timing gear cover retaining bolts and nuts. Install a 3/8"-16NC forged eyebolt in housing. Attach a hoist and remove the front timing gear cover-weight 175 lbs. (80 kg).Install Front Timing Gear Cover
1. Lubricate the lip of crankshaft front seal with clean SAE 30 oil.2. Attach a hoist and position the timing gear cover on the engine. Install the retaining bolts and nuts.3. Install the aftercooler water pump or plate and retaining bolts.4. Trim the timing gear cover gasket flush with the bottom face of cylinder block.5. Connect the turbocharger lubrication line to the front timing gear cover.6. Install the fuel filter drain line.7. Install the oil cooler inlet lines and vent line.concluding steps: a) install vibration damper and pulleyb) install water pumpc) install oil panRemove Front Timing Gears And Plate
preparatory step: a) remove front timing gear cover1. Rotate the crankshaft to top dead center compression stroke No. 1 piston. See LOCATING TOP DEAD CENTER COMPRESSION POSITION FOR NO. 1 PISTON in TESTING AND ADJUSTING.2. Remove the left valve cover and install timing pin in slot in left camshaft housing. 3. Remove the balancer (1). Using tool setup (A), remove bearing from gear. Remove balancer thrust washer.4. Remove the idler gear (2). Using tool setup (B), remove bearing from idler gear. Remove the idler gear thrust washer.5. Remove the aftercooler water pump or plate depending on how the engine is equipped. 6. Remove the front timing gear plate mounting bolts and locks. Remove the front timing gear plate (3).7. Remove the crankshaft gear (4) retaining bolts and locks. Remove the crankshaft gear. 8. Remove the oil line (5).9. Remove the shaft mounting bolts and lock (6). 10. Remove the shaft (7) and camshaft drive idler gear (8).11. Using tool setup (C), remove the bearing from camshaft drive idler gear.Install Front Timing Gears And Plate
1. Using tool setup (C), install bearing in camshaft drive idler gear. Install the idler gear, shaft, retaining bolts and lock on engine. Install oil line.2. Position front timing gear plate on the engine and install mounting bolts and locks. Trim the plate-to-cylinder block gasket flush with the bottom face of block.3. Install the crankshaft gear with chamfer on bore of gear toward rear of crankshaft. Install retaining bolts and locks. 4. Install bearing in idler gear using tool setup (B). Install the thrust washer and idler gear on engine with "V" mark on idler gear aligned with "V" mark on the crankshaft gear.
Always be sure that the No. 1 piston is at top dead center compression stroke; the timing bolt is