WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

CAUTION  If the accessory drive dowel pin has been installed in the accessory drive shaft, the dowel pin must be removed before attempting to remove the gear cover to prevent damage to the accessory drive bushing.

• Disconnect the batteries. Refer to the OEM service manual.
• Remove the fan. Refer to Procedure 008-036 in Section 8.
• Remove the fan drive belts. Refer to Procedure 008-002 in Section 8.
• Remove the water pump belt. Refer to Procedure 008-003 in Section 8.
• Remove the alternator drive belts. Refer to Procedure 013-005 in Section 13.
• Remove the accessory drive pulley. Refer to Procedure 009-004 in Section 9.
• Remove the camshaft support and the thrust bearing. Do not discard the shims. Refer to Procedure 001-009 in Section 1.
• 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 four capscrews which hold the oil pan to the gear cover.

Loosen all remaining oil pan mounting capscrews four to five turns.

Use an overhead hoist or a hydraulic arm to support the engine.

Remove the capscrews which hold the front engine support to the crossmember of the equipment.

Remove the eight capscrews and the front engine support.

CAUTION  Use extreme care when releasing the oil pan gasket from the gear cover to prevent damage to the gasket. If the gasket is damaged, the oil pan must be removed and the gasket replaced. Refer to Procedure 007-025 in Section 7.

Insert a feeler gauge or a shim stock between the gear cover and the oil pan gasket. Move the feeler gauge or the shim stock back and forth to release the gasket from the gear cover.

Remove one capscrew on each side of the gear cover, and install a 7/16 - 20 x 4-inch guide stud in each location to support the cover during removal.

Remove the remaining gear cover capscrews, and remove the gear cover.

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.

Clean the gasket surface of the cylinder block.

Clean the gear cover.

Inspect the gear cover for cracks or other damage.

Measure the accessory drive seal bore.

Accessory Drive Seal Bore Inside Diameter

NOTE: Replace the gear cover if the accessory drive seal bore is not within specifications.

Measure the crankshaft seal bore.

Crankshaft Seal Bore Inside Diameter

NOTE: Replace the gear cover if the crankshaft seal bore is not within specifications.

Measure the accessory drive bushing inside diameter.

Accessory Drive Bushing Diameter

NOTE: Replace the bushing if it is not within specifications. Refer to Procedure 001-066 in Section 1.

Install one 7/16 - 20 x 4-inch guide stud into each side of the gear cover mounting flange to align the cover.

Install the gear cover gasket over the guide studs and the dowel pins.

NOTE: Use a film of Lubriplate® 105, or equivalent, to hold the gear cover gasket in place, if necessary.

Install the gear cover and the mounting capscrews.

Tighten the capscrews to the following torque sequence as illustrated:

Cut off the ends of the gasket even with the oil pan mounting flange.

Mount a dial indicator on the front face of the crankshaft. Place the indicator plunger against the oil seal bore, and set the dial indicator at "0" (zero).

Rotate the crankshaft one complete revolution while monitoring the indicator. Use the accessory drive nut to bar the engine over. The total indicator reading must not exceed 0.38 mm [0.015 in].

If the total indicator reading exceeds 0.38 mm [0.015 in] remove the gear cover. Check the cover and the housing for nicks or burrs.

Clean the gear cover and the housing surfaces thoroughly.

Repeat the gear cover installation procedure and check the total indicator reading again.

Install the front engine support and eight mounting capscrews.

Tighten the capscrews.

Lower the engine to the crossmember. Install and tighten the capscrews which hold the front engine support to the crossmember. Refer to the OEM service manual for torque specifications.

Install the front crankshaft seal. Refer to Procedure 001-023 in Section 1.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

CAUTION  If the accessory drive dowel pin has been installed in the accessory drive shaft, the dowel pin must be removed before attempting to remove the gear cover to prevent damage to the accessory drive bushing.

• 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 camshaft support and the thrust bearing. Install the shims. Refer to Procedure 001-009 in Section 1.
• Install the accessory drive pulley. Refer to Procedure 009-004 in Section 9.
• Install the alternator drive belts. Refer to Procedure 013-005 in Section 13.
• Install the water pump belt. Refer to Procedure 008-003 in Section 8.
• Install the fan drive belts. Refer to Procedure 008-002 in Section 8.
• Install the fan. Refer to Procedure 008-036 in Section 8.
• Connect the batteries. Refer to the OEM service manual.
• Operate the engine and check for leaks and proper operation.