Gear train reassembly and installation
Install crankshaft gear as follows:
Install key if it was removed from crankshaft.
Start timing gear on shaft with timing marks out and slot aligned with key.
Use installer and drive gear on until it seats against crankshaft shoulder.
Reassemble and install cam and balance shafts and gears in reverse of disassembly sequence (para 6-22).
Refer to Figure 6-23 and align cam and balance shaft timing marks. Rotate crankshaft to obtain preliminary
d. Reassemble idler gear assembly as follows:
Place inner thrust washer on forward end of idler gear hub with flat of inner diameter over flat on hub, and
with oil grooves on washer facing hub.
Place small protruding end of idler gear hub through end plate and into counterbore in cylinder block.
Insert two 3/8 inch-16 bolts through idler gear hub and thread them into cylinder block.
Insert 3/8 inch-16 x 1-3/4 inch special bolt through center of idler gear hub and thread it into cylinder block.
Tighten bolt to 40-45 Ib-ft torque. Then remove two pilot bolts.
Lubricate idler gear hub and idler gear bearing with clean engine oil.
Install cam and balance shaft gears (para 6-25).
Position gears so that their timing marks (circle) will align with those on idler gear. Refer to Figure 6-23.
Install idler gear.
Apply a thin film of cup grease to grooved face of outer thrust washer and place washer on gear hub.
Check backlash between mating gears. It should be between .003 and .005 inch between new gears and not
more than .007 inch between used gears.
Install flywheel housing.
Install engine assembly.