5-101.bk Page 21 Friday, March 17, 2006 11:05 AM 7. Install injection pump driving gear (5) by applying a quick, even pressure until gear bottoms onto camshaft gear. Make sure camshaft thrust washer holes are accessible through injection pump driving gear. Wear protective gloves when handling heated gears. PRESS METHOD — CAMSHAFT/INJECTION PUMP DRIVING GEAR INSTALLATION Refer to Figure 5-20. 4. Using an oven (not a torch), heat new camshaft gear and new injection pump driving gear to 400°F (205°C). Do not exceed 400°F (205°C) and do not heat for more than one to two hours. Do not exceed two hours. Position camshaft gear with timing marks facing out, and align keyway with key.
Refer to Figure 5-19. 1. Thoroughly clean and degrease camshaft (3) and camshaft drive gear (1) with a suitable contact cleaner that dries rapidly and leaves no residue. 2. Install a new key (4) in camshaft key slot. 3. Place camshaft in a press, making sure camshaft is supported by plates between journal and first lobe. Approximately 5 tons (4.54 MT) of force is required to press each gear onto the camshaft. When in the press, use suitable plates to support the camshaft between the journal and first lobe. Do not allow camshaft to rest on the floor. 4. Position a new thrust washer (2) on the camshaft. Figure 5-20 — Camshaft Gear Installation, Heat Method 5.
Push downward with a quick, even pressure to install camshaft gear onto camshaft. 5. Prepare the gear bore with Locquic™ Primer T, or equivalent. 6. Apply a bead of Loctite 609, or equivalent, to the gear bore. 7. Using a clean brush, spread Loctite 609 evenly onto the entire surface of the gear bore. The heat-expanded gear bore will begin to transfer heat to the camshaft as soon as the gear bore and camshaft contact each other. This makes it absolutely necessary that the gear be installed in one very rapid motion to the fully seated position. If the gear is allowed to stop on the camshaft part way before fully seating, it will become immovable.
If this occurs, do not press- install the gear. It should be press removed, allowed to cool, and re-installed using the press method. Refer to Figure 5-21. 8. Position gear on camshaft with timing marks facing upward and key slot in gear aligned with key in shaft. Do not attempt to increase clearance between camshaft and gears by sanding gear bores or camshaft. 6. There should be between 0.003–0.012 inch (0.076–0.305 mm) clearance between rear face of gear and thrust washer when measured with thickness gauge. Page 5-21 200 BENCH PROCEDURES