Cummins ISX11.9 CM2250 – Service Manual 001-085   Camshaft Gear, Rear

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.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To reduce the possibility of serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

WARNING  Support the rear of the engine using the rear support attached to the rear of the cylinder block. Failure to support the engine can cause personal injury.

• Disconnect the batteries. Refer to the OEM service manual.
• Remove the fuel pump. Refer to Procedure 005-016 in Section 5.
• Remove the starting motor. Refer to Procedure 013-020 in Section 13.
• Disconnect the crankshaft position sensor. Refer to Procedure 019-365 in Section 19.
• If equipped, remove the rear power take-off.  Refer to Procedure 009-022 in Section 9.
• Support the rear of the engine.
• Remove the transmission. Refer to the OEM service manual.
• Remove the flywheel. Refer to Procedure 016-005 in Section 16.
• Remove the flywheel housing. Refer to Procedure 016-006 in Section 1.
• Remove the rear camshaft idler gear. Refer to Procedure 001-115 in Section 1.
• Remove the electronic control module (ECM) to access the camshaft timing boss. Refer to Procedure 019-031 in Section 19.

Rotate the camshaft to find the slot in the camshaft and insert the timing pin. Refer to Procedure 001-088 in Section 1.

The pin is not correctly seated in the camshaft notch if the colored band is either completely visible outside the block, or is not visible at all.

NOTE: This will prevent the camshaft from rotating when the rear camshaft gear capscrews are removed.

Remove the five capscrews and clamping plate from the rear camshaft gear.

Remove the rear camshaft gear from the camshaft.

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

Inspect the bore of the gear for frets or burrs.

Remove any burrs with a fine grade abrasive pad such as Scotch-Brite™ 7448, a fine honing stone, or equivalent.

If the frets, burrs, or raised material can not be removed, replace the gear.

Measure the camshaft gear bore inside diameter.

Rear Camshaft Gear Bore Inside Diameter

Inspect the camshaft nose for frets or burrs.

Remove any burrs with a fine grade abrasive pad such as Scotch-Brite™ 7448, a fine honing stone, or equivalent.

If frets or burrs can not be removed, replace the camshaft.

Inspect the thrust surface of the camshaft for grooves or heavy wear.

Measure the camshaft gear journal outside diameter.

Rear Camshaft Gear Journal Outside Diameter

CAUTION  The gear part number must be facing away from the camshaft when the gear is installed to prevent engine damage.

Install the camshaft gear onto the rear of the camshaft with the part number facing out.

The camshaft gear must spin freely on the camshaft.

Install the rear camshaft idler gear. Refer to Procedure 001-115 in Section 1.

Install the clamping plate onto the rear of the camshaft. Hand tighten the five capscrews through the clamping plate and into the camshaft.

Apply pressure on the cam gear in a clockwise direction to take the lash out of the gear train.

CAUTION  Failure to check the engine timing can cause severe engine damage.

Time the engine. Refer to Procedure 001-088 in Section 1.

Rotate the camshaft to find the slot in the camshaft and insert the timing pin. Refer to Procedure 001-088 in Section 1.

The pin is not correctly seated in the camshaft notch if the colored band is either completely visible outside the camshaft, or is not visible at all. This will prevent the camshaft from rotating when the rear camshaft gear capscrews are tightened.

Tighten the rear camshaft capscrews in a star pattern after timing the engine.

Tighten the rear camshaft capscrews in a star pattern.

Repeat the torque sequence three more times.

Remove the camshaft and crankshaft timing pin.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To reduce the possibility of serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

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.

• Install the electronic control module (ECM). Refer to Procedure 019-031 in Section 19.
• Install the flywheel housing. Refer to Procedure 016-006 in Section 1.
• Install the flywheel. Refer to Procedure 016-005 in Section 16.
• Install the transmission. Refer to the OEM service manual.
• If equipped, install the rear power take-off. Refer to Procedure 009-022 in Section 9.
• Connect the crankshaft position sensor. Refer to Procedure 019-365 in Section 19.
• Install the starting motor. Refer to Procedure 013-020 in Section 13.
• Install the fuel pump. Refer to Procedure 005-016 in Section 5.
• Connect the batteries. Refer to the OEM service manual.
• Operate the engine to normal operating temperature and check for leaks.