NUMBER: 2 10-09 S.M. REF.

: Listed in Table ENGINE: DD15 DATE: February 2009

SUBJECT: CAMSHAFT TIMING

ADDITIONS, REVISIONS, OR UPDATES

Publication Number Platform Section Title Change Page Number(s)
DDC-SVC-MAN-0002 EPA07 DD15 1.16 gear train and The timing tool number 1–110
engine timing for the front and rear
camshafts has been
changed. A new
camshaft timing section
has been added.
NOTE: Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle.
GEAR TRAIN AND ENGINE TIMING
The gear train is located at the rear of the engine. The gear train consists of intake and exhaust camshaft
gears, idler gears No. 1, 2, 3, 4, and 5, crankshaft gear, oil pump gear, fuel pump gear, air compressor
gear, and axial power turbine gear.
1. Idler Gear No. 1
2. Idler Gear No. 2
3. Idler Gear No. 3
4. Idler Gear No. 4
5. Idler Gear No. 5
6. Air Compressor Gear
7. Fuel Pump Gear
8. Axial Power Turbine Gear
9. Crankshaft Gear
10. Oil Pump Gear
11. Camshaft Gear Exhaust
12. Camshaft Gear Intake
A. Level A
B. Level B
C. Level C
x. To Front of Engine
The gear train on the DD Series engines is located at the rear of the engine and has three levels. Level A
consists of the outer most gears (closest to the flywheel), level B consists of the middle gears, and level
C consists of the forward most gears (closest to the block). The gears in the gear train are both directly
and indirectly driven by the crankshaft gear.
□ Level A: The outer gears include the crankshaft gear which drives the No. 1 outer idler gear
and the oil pump. The No. 4 idler gear is on the crankshaft gear and the axial power turbine
drives the No. 4 idler gear when the Axial Power Turbine (APT) is creating power. The APT
can add additional torque to the crankshaft through No. 4 idler gear up to 260 N·m (192 lb·ft).
These gears are all helical cut.
□ Level B: The middle gears include No. 1 inner idler gear which drives the air compressor gear
and the No. 2 idler gear. The No. 2 idler gear drives the high pressure fuel pump and the No. 3
outer idler gear. These gears are all straight cut.
□ Level C: The inner gears include the No. 3 inner idler gear which drives the No. 5 idler gear.
The No. 5 idler gear drives both intake and exhaust camshafts. These gears are all straight cut.
Gear train noise is an indication of excessive gear lash, chipped or burred gear teeth. Therefore, when
noise develops in a gear train, the gear train needs to be inspected. A rattling noise usually indicates
excessive gear lash. A whining noise indicates too little gear lash.
The power steering pump can be mounted in two places. If the engine is equipped with a single-cylinder
air compressor, it will be mounted to the front of the air compressor. If the engine is equipped with a
two cylinder air compressor, then it will be mounted on the back of the gear case to the fuel pump.
GEAR TRAIN AND ENGINE TIMING WITH GEAR TRAIN REMOVED
Time the gear train as follows:

NOTE:
Do not remove timing tools until all the gears have been installed.

NOTE:
Coat the inside of the gears, bushings and gear train with clean oil before installation.

1. Install timing tool (1) (W470589054000) into the holes at the rear of the camshaft frame and
secure to the camshaft frame with two bolts.
 2. Install timing tool (1) (W470589054000) into the holes at the front of the camshaft frame and
secure to the camshaft frame with one bolt.

NOTE:
Timing marks are etched on the exhaust and intake gears.

3. Ensure timing marks on camshaft gear are at TDC for intake and exhaust gear.
4. Rotate the crankshaft to top dead center (TDC) on cylinder No. 1. Lock tool J-48630 into
place with bolt.

5. If removed, install idler gear No. 5 with tool J-47486.

6. Install two bolts into idler gear No. 5. Remove shoulder bolt J–47486 and final torque to
60–65 N·m (44–48 lb·ft).
 7. Install timing tool J–47487 on idler gear No. 3.

NOTE:
Ensure timing mark on spindle and gear for idler gear No. 3 align.

8. Install idler gear No. 3 with spindle and tool J–47487 onto cylinder block.
9. Install two bolts into the spindle and idler gear No. 3; snug the bolts.

NOTE:
When idler gear No. 3 and timing tool J–47487 are installed to the gear case, timing tool J–47487
should come off of the gear with ease. If the timing tool is not easily removed, that is an indication
that the gears are not timed.

10. Check the gear lash between idler gear No. 3 and idler gear No. 5.
11. Install a dial indicator onto gear case and position the stem to rest between the teeth on idler
gear No. 3; zero out the dial indicator.
12. Hold idler gear No. 5 with a screwdriver to check gear lash.
13. The lash reading on the dial indicator should be 0.77 - 0.345 mm (0.003-0.013 in.).
14. When correct gear lash is established, torque idler gear No. 3 to 60–65 N·m (44-48 lb·ft).
 15. Install spindle and idler gear No. 2 onto cylinder block with three bolts.
Torque bolts to 100 N·m (73 lb·ft).

NOTE:
For ease of installation on idler gear No. 1, roll the gear into crankshaft gear.

16. Install the spindle and idler gear No. 1 and thrust washers onto cylinder block with three
bolts. Torque the bolts to 100 N·m (73 lb·ft).

NOTE:
When installing No. 4 idler gear, verify that the part number on the gear is facing the block.

17. Install spindle and idler gear No. 4 and thrust washers onto cylinder block with four bolts.
Torque the bolts to 100 N·m (73 lb·ft).
18. With J-47487 and J48630 installed and the gear train completely assembled, use timing tool
(W470589054000) installed into the holes in the rear of the camshaft frame. Verify camshaft
gear timing marks are aligned with marks on the timing tool.

19. Remove timing tools from gears and camshaft frame.

CHECKING AND ADJUSTING GEAR LASH WITH CYLINDER HEAD AND CAMSHAFT FRAME
REMOVED
This is performed with camshaft housing removed. Check and adjust as follows:
1. Remove the camshaft housing if not already removed. Refer to section "Removal of Camshaft
Housing."
2. Install a magnetic base-dial indicator gauge on engine block.

3. Set the dial indicator on the number 5 gear tooth.

4. Turn idler gear number 5 counterclockwise (viewed from front of engine) until “0” lash is
present, then zero the gauge on the dial indicator.
5. Check the gear lash by turning the idler gear number 5 stop to stop, verify that the lash reading
on the dial indicator is 0.77 - 0.345 mm (0.003-0.013 in.).
6. If gear lash is incorrect, continue with the following steps to adjust.
7. Remove access cover to the number 3 idler bolts.
8. Loosen the two number 3 idler gear bolts and then snug by hand.
9. Turning idler gear number 5 by hand will change gear lash from zero lash to maximum lash.
NOTE:
Rotating idler gear number 5 counterclockwise (viewed from front of engine) will result in 0 lash.
Rotating idler gear number 5 clockwise (viewed from front of engine) will result in maximum lash.

10. Install a magnetic base-dial indicator gauge on engine block.

11. Set the dial indicator on the number 5 gear tooth.

12. Turn idler gear number 5 counterclockwise (viewed from front of engine) until “0” lash is
present, then zero the gauge on the dial indicator.
13. Push idler gear number 5 clockwise (viewed from front of engine) till desired gear lash is
present.
14. Tighten the two bolts on the number 3 gear.
15. Check gear lash by turning idler gear number 5 stop to stop; verify the lash reading on the dial
indicator should be 0.77 - 0.345 mm (0.003-0.013 in.).
16. If gear lash is OK, then final torque idler number 3 bolts to 60–65 N·m (44-48 lb·ft).
17. Install access cover and tighten.
18. Install the camshaft housing as needed. Refer to section "Installation of Camshaft Housing."
CAMSHAFT TIMING VERIFICATION
Time the camshaft as follows:
1. Remove the rocker cover. Refer to section 1.9 "Removal of Rocker Cover.".
2. Bar the engine to top dead center (TDC) with J-46392 (3), #1 with the #6 valve in overlap and
the dot (2) that is located inside the flywheel tone ring is aligned with the edge of the pointer (1).

3. Locate the mark on the camshaft and mark the top of the corresponding gear tooth with
a light colored paint pen.
4. Remove the Crankshaft Position Sensor from the flywheel housing.
5. Install the TDC locating pin (W470589001500) through the crankshaft position sensor hole
in the flywheel housing and engage into the flywheel notch.

6. Install the rear timing tool (1) (W470589054000) onto the camshaft housing.
7. Install the front timing tool (1) (W470589054000) into the grooves cut into the cams and
pin it into the camshaft housing with a bolt.

8. Verify that the marks on the gear teeth match the marks on the timing tool.
[a] If the marks do not match, research the root cause of incorrect camshaft timing. Refer
to section 1.16.
TIMING THE CAMSHAFTS WITH THE GEAR TRAIN INSTALLED
Time as follows:
1. Bar the crankshaft over to TDC cylinder No. 1 and lock with W470589001500 through the
crankshaft position sensor hole.
2. Install timing tool No. 1 onto the rear of the cam frame.
3. Locate the mark on the camshafts and mark the top of the corresponding gear tooth with
a light colored paint pen.
4. Lubricate the camshafts and camshaft housing journals with clean engine oil.

NOTE:
The intake camshaft has the tone wheel and must be installed on the intake side of the engine.

5. Install the camshafts into the camshaft housing in their respective locations lining up the
marked cam gear teeth with the mark on the timing plate.
6. Install the front timing tool (1) (W470589054000) into the grooves cut into the camshafts to
verify correct cam timing. Any resistance felt while installing or removing could indicate the
camshafts being out of time. Install a bolt into the tool to hold it into place.

7. To install the camshaft and rocker assemblies, refer to section 1.4 Camshaft and Rocker Shaft
Assemblies.
ADDITIONAL SERVICE INFORMATION
Additional service information is available in Power Service Literature.

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