DISASSEMBLY AND ASSEMBLY
CRANKSHAFT AND GEAR
1202 & 1204-11
Ratchet Box Wrench
Bearing Puller Attachment
a) remove hydraulic pump gear train
b) remove timing gear cover
c) remove pistons
Install a 3/4" - 16 NC bolt in the gear end of the
crankshaft. Install two 5/8- 18 NF bolts in the
flywheel end of the crankshaft. Fasten a hoist
to the crankshaft.
Remove main bearing caps (1).
Remove the crankshaft from the cylinder
block. Weight of the crankshaft is approxima-
tely 65 kg (145 lb.).
Remove main bearings (2) from the block and
from the caps. Remove the thrust bearings.
Use tooling (A) to remove gear (3) from the
1201 & 1204-12
Heat the crankshaft gear to a maximum tem-
perature of 315°C(600°F). Install the gear on
the crankshaft with the C mark on the gear
toward the pulley end of the crankshaft.
Clean the surfaces on the cylinder block for the
main bearings. Install the upper halves of the
main bearings in the block. Put clean engine oil
on the bearings.
Turn the camshaft so the C mark on the
camshaft gear will be toward the C mark on
the crankshaft gear when the crankshaft is in-
stalled. Put the crankshaft in position in the
cylinder block with a hoist. Make sure the tim-
ing marks on the camshaft gear and crankshaft
gear are in alignment as shown.
Clean the Nos. 1 and 5 main bearing caps.
Install new bearings in the caps. Put clean en-
gine oil on the bearings. Temporarily install the
caps to hold the crankshaft in place.