• Remove the front engine mount. Refer to the OEM service manual.
• Remove the vibration damper. Refer to Procedure 001-052 in Section 1.
• Remove the crankshaft pulley. Refer to Procedure 001-022 in Section 1.
• Remove the accessory drive pulley. Refer to Procedure 009-004 in Section 9.
• Remove the front crankshaft seal. Refer to Procedure 001-023 in Section 1.
• Remove the accessory drive seal. Refer to Procedure 001-003 in Section 1.
• Remove the gear cover. Refer to Procedure 001-031 in Section 1.

Install the crankshaft gear puller, Part Number 3375840, and jaw onto the gear, Part Number 3824284.

Turn the pressure screw clockwise to remove the gear.

CAUTION  Do not damage the crankshaft when removing the key.

Use a flat chisel and a mallet to remove the crankshaft gear key.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Clean the gear with solvent. Dry with compressed air.

Inspect the crankshaft gear for cracks and broken or chipped teeth.

Remove any burrs with a fine crocus cloth.

Inspect the crankshaft gear fit area for burrs.

Remove any burrs with a fine crocus cloth.

Scratches must not exceed 0.79 mm [0.031 in] depth, and must be at least 3.2 mm [0.125 in] apart.

Measure the crankshaft gear bore.

Crankshaft Gear Bore Inside Diameter

Replace the crankshaft gear if it does not meet diameter specifications.

Measure the crankshaft gear fit area outside diameter.

Crankshaft Gear Fit Area Outside Diameter

Replace the crankshaft if it does not meet diameter specifications.

Use a leather mallet to install a new key into the crankshaft keyway.

Heat the gear in an oven for a minimum of 1 hour at 204°C [400°F] not to exceed 4 hours maximum.

CAUTION  Wear protective gloves when handling parts that have been heated to prevent personal injury.

Remove the gear from the oven.

NOTE: The gear must be installed within 30 seconds after being removed from the oven.

NOTE: The timing mark (1) and the gear part number (2) must be facing away from the crankshaft.

Align the gear keyway and the key, and install the gear firmly on the crankshaft.

NOTE: If any gears were rotated, it will be necessary to align the timing marks of the crankshaft and the camshaft gears.

• Install the gear cover. Refer to Procedure 001-031 in Section 1.
• Install the accessory drive seal. Refer to Procedure 001-003 in Section 1.
• Install the front crankshaft seal. Refer to Procedure 001-023 in Section 1.
• Install the accessory drive pulley. Refer to Procedure 009-004 in Section 9.
• Install the crankshaft pulley. Refer to Procedure 001-022 in Section 1.
• Install the vibration damper. Refer to Procedure 001-052 in Section 1.
• Install the front engine mount. Refer to the OEM service manual.
• Operate the engine until it reaches a temperature of 82°C [180°F], and check for lubricating oil leaks.