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SERIES 60 GEAR CASE COVER

The gear case cover and gear case housing bolt together at the front of the engine to form a sealed compartment for the engine gear train. See Figure 20132 . ‪

Engine Gear Case and Cover

For Series 60 2002 engines with EGR sytems see Figure 42772

Engine Gear Case and Cover for Series 60 2002

Gear Case Cover-mounted Components

The gear case cover also serves as a retainer for the crankshaft front oil seal. See Figure 20133 . ‪

Crankshaft Front Oil Seal

Several components that are mounted to the gear case cover include the water pump (pre-1991 engines only), accessory drive assembly, and fan support bracket See Figure 20134 . ‪

Gear Case Cover-mounted Components

The front engine support is bolted to the front of the gear case cover, directly behind the crankshaft pulley and vibration damper. See Figure 20135 and see Figure 37000 . ‪

Typical Front Engine Support

1. Bracket, Engine Mounting ‪

6. Screw, Isolator Mounting ‪

2. Short Mounting Bracket ‪

7. Washer ‪

3. Front Heat Exchanger Support Mounting Bracket ‪

8. Heat Exchanger Support ‪

4. Long Mounting Bolt ‪

9. Bracket, Rear Engine Mounting ‪

5. Isolator, Heat Exchanger ‪

Typical Front Engine Support Heat Exchanger-Cooled Pleasure Craft Marine

Several access covers are provided on the gear case cover for service of the engine without removing the gear case cover. Removal of the camshaft drive gear access cover will allow the removal of the camshaft drive gear-to-camshaft bolt for camshaft and cylinder head removal without removing the gear case cover. See Figure 20136 . ‪

Camshaft Drive Gear Access Cover

The fan support bracket includes the access cover for the adjustable idler gear. See Figure 20137 . ‪

Fan Support Bracket

With the fan support bracket and the camshaft drive gear access cover removed, the gear lash between the adjustable idler gear and the camshaft drive gear can be measured and adjusted Refer to section . ‪

On vehicles without power steering, an access cover is provided for inspection of the air compressor drive gear. See Figure 20138 . ‪

Air Compressor Drive Gear Access Cover

On some vehicles equipped with power steering, the power steering hydraulic pump is mounted to the gear case cover in the place of the access cover, and is driven by a short coupling that fits in the splined hole in the center of the air compressor drive gear. The pump is installed with a gasket. ‪

Repair or Replacement of Gear Case Cover

To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure 24155 . ‪

Flowchart for Repair or Replacement of Gear Case Cover

Removal of Engine Gear Case Cover

With the engine mounted on an overhaul stand. Remove the gear case cover as follows: ‪

NOTICE:

Do not hit the face of the damper to loosen it. Damage to the internal components may result. The oil pan cannot be used to support the front of the engine in a vehicle, as its thermoplastic construction will not support the weight. ‪

  1. Drain the engine oil and remove the engine oil pan. Refer to section , for oil draining and refer to section .
  2. Loosen the fan hub mounting bolts. Loosen the fan adjusting bolt. Back the adjuster off far enough to remove the drive belts. Remove the fan and fan hub assembly. Refer to section .
  3. Loosen the alternator mounting bolts. Remove the alternator drive belts, alternator, and mounting brackets (if so equipped). Refer to section . See Figure 20139 .

    Alternator and Related Parts

  4. Loosen the air conditioner compressor and mounting brackets (if so equipped). Refer to OEM guidelines.
  5. Remove the five fan support bolts. See Figure 20140 .

    Fan Support Bolt Location

  6. Remove the water pump assembly. Refer to section for front mounted water pump. Refer to section for gear case mounted.
  7. Remove the power steering pump (if so equipped). Refer to OEM guidelines.
  8. Remove the crankshaft pulley. Refer to section .
  9. Remove the vibration damper. Refer to section .
  10. Remove the front engine mount by removing the four bolts securing the front engine mount to the gear case cover.
  11. Loosen and remove the five bolts that secure the accessory drive assembly to the gear case cover. See Figure 20141 .

    Accessory Drive Assembly

  12. Remove the accessory drive assembly by pulling it straight out of the gear case cover to avoid damaging the rubber O-ring. See Figure 20141 .
  13. There are a total of 34 bolts that secure the gear case cover to the gear case. Bolts 17, 18, 19 and 20 were removed with the front engine mount. Bolts F1 through F5 were removed in a previous step; refer to step . Loosen and remove bolts 1 through 16, 21, 22 (see note).

    Gear Case Cover Bolt Arrangement (Front)

    Note: Bolts 21 and 22 are rear bolts on pre-1991 engines.

    1. Remove the SRS. Refer to section .
    2. Remove the air compressor drive assembly by removing the six bolts on the back of the gear case on the intake side of the engine located around the air compressor drive assembly. See Figure 20143 .
    3. Gear Case Cover Bolt Arrangement (Left Rear)

    4. Remove the bolts on the back of the gear case on the water pump (right) side of the engine. See Figure 20144 .
    5. Gear Case Cover Bolt Arrangement (Right Rear)

  14. For Series 60 2002 Engines remove gear case cover from gear case as follows: ‪

  15. Remove Compact Gear Train Assembly. Refer to Section 1.23.
  16. Remove 21 bolts securing Gear Case Cover from Gear case. See Figure 42857

    Gear Case Cover Bolt Location

  17. Support the gear case cover with a suitable lifting device, using the front engine lift bracket. See Figure 20150 .

    1. Engine Lifter Bracket ‪

    3. Gear Case Housing ‪

    2. Gear Case Cover ‪

    Engine Gear Case Cover Support

    Note: There is a rubber O-ring installed between the center of the bull gear hub and the gear case cover. The O-ring may adhere to the cover when it is removed. Be sure the O-ring is not lost. See Figure 20146 .

    Bull Gear O-ring

  18. Tap the gear case cover with a fiber mallet or plastic hammer to loosen it from the gear case. Remove the engine gear case cover.
Inspection of Gear Case Cover

Inspect the gear case cover as follows: ‪

  1. Clean all of the old gasket sealer from the mating surfaces of the gear case and gear case cover. Refer to General Information , "Cleaning".
  2. Clean the gasket material from the mating surfaces of any components or access covers that were removed from the gear case cover, and the gear case cover itself.

    EYE INJURY

    To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) air pressure.

  3. Clean all of the removed parts except the electrical components with clean fuel oil and dry with compressed air.

    Note: Any time the gear case cover is removed, the crankcase oil seal must be replaced. Install the new front oil seal after the gear case cover has been installed to the engine.

  4. If necessary, remove the crankshaft front oil seal at this time. Refer to section . Inspect the gear case cover for stress cracks or breaks in the casting. Refer to section . Repair or replace as necessary. Refer to section .
  5. Inspect all O-rings for signs of dryness or splitting. Replace as necessary.

Installation of Gear Case Cover

Perform the following steps for gear case installation: ‪

  1. Apply a continuous 1/16 in. bead of Gasket Eliminator PT-7276 (Loctite 518) or equivalent to the mating surface of the gear case.

    Note: Gasket eliminator cures with the absence of air. The length of time between gear case cover installation and torquing the bolts that secure the gear case cover to the gear case should be kept to a minimum.

  2. Install two guide studs, J 36107 , to the gear case. See Figure 25897 .

    1. Front Gear Case Cover ‪

    4. Locating Dowel (Round) ‪

    2. Front Engine Lift Bracket ‪

    5. Locating Dowel (Diamond) ‪

    3. Front Gear Case Housing ‪

    Gear Case Cover Guide Stud Location

  3. Support the gear case cover with a suitable lifting device, using the front engine lift bracket. See Figure 20150 .
  4. Position the gear case cover on the guide studs and slide it forward. Index the two dowels in the gear case. See Figure 25897 .
  5. For Series 60 2002 Engines there are 21 bolts that secure gear case cover to to gear case. Torque bolts No.1 through 19 to 65 Nm (48 lbft). Torque bolts 20 and 21 to 113 Nm (83 lbft). See Figure 42816 .

    Gear Case Cover Bolt Torque Sequence Series 60 2002 Engine

  6. There are 34 bolts that secure the gear case cover to the gear case (including five for the fan support bracket). Install them as follows:

    NOTICE:

    With gasketless parts such as the gear case cover; the torque values and tightening sequences are critical to prevent parts warpage. ‪

    1. Install the shorter bolts, No. 1 through 16, 21, 22 (see note), in various locations at the front of the gear case cover. Finger-tighten them. Remove the guide studs when installing bolts 7 and 14. See Figure 20142 .
    2. Note: Bolts 21 and 22 are rear bolts on pre-1991 engines.

      Gear Case Cover Bolt Torque Sequence (Front)

    3. Torque bolts 1 through 16, 21, 22 (see note), to 58-73 Nm (43-54 lbft).
    4. Install the front engine mount to the gear case cover. Install the four, longer, front engine mount-to-gear case cover bolts, finger-tight.
    5. Torque bolts 17, 18, 19 and 20 to 160-200 Nm (118-148 lbft). See Figure 20142 .
    6. Bolts F1 through F5 are fan support bracket bolts. Install the fan support bracket and torque bolts F1, F2 and F3 to 58-73 Nm (43-54 lbft). Torque bolts F4 and F5 to 160-200 Nm (118-148 lbft).
    7. Install the six bolts on the intake (left) side of the engine around the air compressor drive. Torque the bolts to 58-73 Nm (43-54 lbft), using the sequence. See Figure 20148 .
    8. Air Compressor Drive Torque Sequence

    9. Install the SRS to the gear case; refer to section .
    10. Install the two rear mounted bolts (pre - 1991 engines only) bolts on the exhaust (right) side of the engine. Torque the number 2 and 3 bolts to 58-73 Nm (43-54 lbft) torque. See Figure 20144 .
    11. Gear Case Cover Bolt Torque Sequence (Right Rear)

  7. Install a new crankshaft front oil seal. Refer to section .
  8. Install the accessory drive assembly to the gear case. Refer to section .
  9. Install the vibration damper to the crankshaft. Refer to section .
  10. Install the crankshaft pulley to the end of the crankshaft. Refer to section .
  11. Install the water pump assembly. Refer to section for gear case mounted. Refer to section for front mounted.
  12. Install a new gasket between the power steering pump cover and the gear case (if so equipped).
  13. Install the power steering pump cover to the gear case cover with the six bolts. Tighten the bolts progressively in a star-shaped pattern to draw the power steering pump in evenly. Torque the bolts to 30-38 Nm (22-28 lbft), using a star-shaped pattern.
  14. Insert a new gasket between the camshaft drive gear access cover and the gear case cover.
  15. Install the camshaft drive gear access cover to the gear case cover. Torque the bolts to 30-38 Nm (22-28 lbft), using the tightening sequence. See Figure 20149 .

    Access Cover Bolt Torque Sequences

  16. Install the air conditioner compressor and brackets. Install the air conditioner compressor drive belt. Refer to OEM guidelines.
  17. Install the alternator and brackets. Refer to section . Install the alternator drive belts. Refer to section .
  18. Adjust the alternator and air conditioner compressor drive belts to the specifications. Refer to section .
  19. Install the engine oil pan. Refer to section . Fill the crankcase with recommended lubricating oil. Refer to section .

Installation of Acoustical Gear Case Covers

Install acoustical covers as outlined below. See Figure 24784 , and see Figure 24875 , for Group A installations with accessory drive. See Figure 24786 and see Figure 24876 for installation on Group B without accessory drive. See Figure 24785 and see Figure 24876 for typical Group C installations. See Figure 24787 and see Figure 24873 for Group D installations. ‪

  1. Using required fasteners, install front gear case acoustical cover and accessory drive acoustical cover. Tighten bolts and nut(s) to the torque values: listed in Table .
  2. Using required fasteners and clips, install right rear and left rear covers. Tighten bolts and nut(s) to the torque values listed in Table .

    Bolt or Nut Size

    Required Torque

    M6 x 1.0 ‪

    13-16 Nm (10-12 lbft) ‪

    M8 x 1.25 ‪

    30-38 Nm (22-28 lbft) ‪

    M10 x 1.5 ‪

    58-73 Nm (43-54 lbft) ‪

    Acoustical Cover Fastener Torque Values

    1. Nut ‪

    4. Acoustical Cover ‪

    2. Bolt ‪

    5. Gear Case ‪

    3. Acoustical Cover Clip ‪

    6. Gear Case Cover ‪

    Typical Group A Front Acoustical Cover Installation (With Accessory Drive)

    1. Gear Case Cover ‪

    5. Bolt ‪

    2. Gear Case ‪

    6. Acoustical Cover ‪

    3. Acoustical Cover Snap ‪

    7. Acoustical Cover ‪

    4. Acoustical Cover Clip ‪

    8. Nut ‪

    Typical Group A Rear Acoustical Cover Installation (With Accessory Drive)

    1. Nut ‪

    4. Acoustical Cover ‪

    2. Bolt ‪

    5. Gear Case ‪

    3. Acoustical Cover Clip ‪

    6. Gear Case Cover ‪

    Typical Group B Front Acoustical Cover Installation (No Accessory Drive)

    1. Gear Case Cover ‪

    5. Bolt ‪

    2. Gear Case ‪

    6. Acoustical Cover ‪

    3. Acoustical Cover Snap ‪

    7. Acoustical Cover ‪

    4. Acoustical Cover Clip ‪

    8. Nut ‪

    Typical Group B Rear Acoustical Cover Installation (No Accessory Drive)

    1. Nut ‪

    4. Acoustical Cover ‪

    2. Bolt ‪

    5. Gear Case ‪

    3. Acoustical Cover Clip ‪

    6. Gear Case Cover ‪

    Typical Group C Front Acoustical Cover Installation

    1. Gear Case Cover ‪

    5. Bolt ‪

    2. Gear Case ‪

    6. Acoustical Cover ‪

    3. Acoustical Cover Snap ‪

    7. Acoustical Cover ‪

    4. Acoustical Cover Clip ‪

    8. Nut ‪

    Typical Group C Rear Acoustical Cover Installation

    1. Bolt ‪

    4. Acoustical Cover ‪

    2. Nut ‪

    5. Gear Case ‪

    3. Acoustical Cover Clip ‪

    6. Gear Case Cover ‪

    Typical Group D Front Acoustical Cover Installation

    1. Gear Case Cover ‪

    5. Bolt ‪

    2. Gear Case ‪

    6. Acoustical Cover ‪

    3. Acoustical Cover Snap ‪

    7. Acoustical Cover ‪

    4. Acoustical Cover Clip ‪

    8. Nut ‪

    Typical Group D Rear Acoustical Cover Installation