Workshop Manual

GEAR HOUSING

1
Gear Housing

Disassembly Notes . ................................................................................................................................. 9-2

2
Inspections and Measurements................................................................................................................. 9-4

Specifications............................................................................................................................................ 9-4 3

Assembly................................................................................................................................................... 9-8
4

9-

10

11

12

13

14

15

16

17

MWM INTERNATIONAL Motores

Publication P/N: 9.612.0.006.716.4 – 03/09
 Workshop Manual

Disassembly Notes

1. Remove the belt acessories by a wrench to loose Before disassembling the pulley, lock the flywheel
the tightener. and crankshaft assembly with the special tool MIM
No. D7000600C1 to avoid loose of timing gear
sinchronism.

2. Remove the fan pulley bolts and then remove the

pulley. Remove the acessory pulley.
Loosen the bolts of crankshaft pulley.
Remove the crankshaft pulley and damper set.

9-

3. Remove the pulley and tightener support.

Remove the front seal.

MWM INTERNATIONAL Motores

Publication P/N: 9.612.0.006.716.4 – 03/09
Workshop Manual

GEAR HOUSING

Remove the front cover mounting bolts and then 1

remove the cover.

Remove and replace the front cover gasket. 6

9-

10

11

12

13

14

15

16

17

MWM INTERNATIONAL Motores

Publication P/N: 9.612.0.006.716.4 – 03/09
 Workshop Manual

Inspections and Measurements

Visually check damper and pulley(s).

Visually check gears. Check for wear signs or cracks
on the base of the teeth.
Presenting those defects, the gears must be
replaced.
Measure the components of the gear housing
according to the following illustration:

9-
Specifications

Idle gear bearing

Measurements mm
Ø nominal 44.995 -45.011
Gear clearances mm
Radial. 0.013 - 0.075.
Axial 0.06 - 0.14

9-3-2

MWM INTERNATIONAL Motores

Publication P/N: 9.612.0.006.716.4 – 03/09
Workshop Manual

GEAR HOUSING

Thrust ring (for intermediate ring)

E
E (mm) MIM nr. 3

3.41 - 3.45 9.610.0.433.004.4

3.46 - 3.50 9.610.0.433.005.4
3.52 - 3.56 9.610.0.433.006.4 4

6
Idle gear
Ø hole mm
7
Without bushing 50.000 - 50.016
With bushing 45.024 - 45.076
Quantity of teeth 61
8

9-

10

11

12

Crankshaft front gear

Ø hole 59.994 - 60.019 mm 13

Quantity of teeth 36

14

15

16

17

MWM INTERNATIONAL Motores

Publication P/N: 9.612.0.006.716.4 – 03/09
 Workshop Manual

High pressure pump gear

Ø hole 25.000 - 25.033 mm
Quantity of teeth 30

Camshaft front gear

(Camshaft to fuel pump driving gear)
Ø hole 50.000 - 50.032 mm
Quantity of teeth 80

9-

Camshaft back gear

(Camshaft timing gear)
Ø hole 52.00 - 52.03 mm
Quantity of teeth 72

Air compressor gear

Ø hole 30.00 - 30.033 mm
Quantity of teeth 32

MWM INTERNATIONAL Motores

Publication P/N: 9.612.0.006.716.4 – 03/09
Workshop Manual

GEAR HOUSING

Gears clearances 1

ID DENOMINATION
A Crankshaft gear 2
B Idle gear
C High pressure fuel pump gear
3
D Camshaft back gear
E Water pump gear
F Air compressor gear 4
G Oil pump gear
H Balancer unit driving gear (*)
I/J Balancer unit gears (*) 5

K Camshaft front gear

* For 4.12 engines
6

E
8
Z = 18
K
Z = 80
9-

F
Z = 32
10
C
Z = 30

D 11
B Z = 72
Z = 61

A
Z = 36
12

G
Z = 26
H
Z = 76 13

14

I
J
Z = 38
Z = 38
15

16
Gears backlash 0.05-0.18 mm

17

MWM INTERNATIONAL Motores

Publication P/N: 9.612.0.006.716.4 – 03/09
 Workshop Manual

Assembly

Lock the engine with the special tool No. D7000600C1. Install the gear housing tightening the fixation bolts
With the starter removed install the tool as indicated. crosswise according to the specification.
Torque: 15 ± 5 Nm

Install the idle bearing without the disk and the thrust
ring for a perfect centralization of the intermediary
piece. ! Attention: The centralization of the gear
housing is important to guarantee
the specified clearances of the
distribution gears.
9-
! Attention: When removing/installing only
water pump, lock the cankshaft
and timing gears.

Install the water pump, tightening according to the

specification.Take care to do not damage the sealing
ring.
Torque: 20 ± 5 Nm
Place the gear housing to block gasket.

MWM INTERNATIONAL Motores

Publication P/N: 9.612.0.006.716.4 – 03/09
Workshop Manual

GEAR HOUSING

Install lubricant oil pump tightening according to the 1

specification.Take care to do not damage the sealing
ring.
Torque: 20 ± 5 Nm
2

Assembly the idle gear.

6

Install lubrication pipes tightening according to the

specification (electronic engine shown).
7
Torque: 5 ± 5 Nm

9-

10
To assembly the gears in the correct timing position,
use a screwdriver to make short turns. Observe the
timing gear marks. 11

Assembly camshaft gear and tighten the bolts

according to the specification. 12

Torque: 1st: 15 to 25 Nm
2nd: 28° to 32° (torque range from
35 to 65 Nm) 13

14

15

16

17

MWM INTERNATIONAL Motores

Publication P/N: 9.612.0.006.716.4 – 03/09
 Workshop Manual

Install the bolts of the idle bearing. Install a new O-ring to the air compressor and apply
vaseline to avoid damages during installation.

Torque: 55 to 65 Nm
Install the thrust ring of the idle gear.The two grooves Install the bolts to the air compressor and tighten to
must stay towards the side of the shaft. There are 3 the specified torque.
different thickness of thrust ring in order to guarantee
the axial clearance of the idle gear. Torque: 40 to 50 Nm

9-10

Air Compressor Replacement/

Install the bolts to the air compressor bracket.
Installation
Torque: 14 to 26 Nm
Remove the nut and its protector and install the gear
and its nut applying the torque.
Torque: 210 to 250 Nm

MWM INTERNATIONAL Motores

Publication P/N: 9.612.0.006.716.4 – 03/09
Workshop Manual

GEAR HOUSING

Tighten all mounting bolts of timing gears with the 1

specified torques. See special torques table in A B
Appendix A.
2

5
Install high pressure pump to the gear housing.

Measure the clearance between high pressure pump

timing gear and camshaft gear.
7

9-11

10
Tighten the mouting bolts.
Torque: 45 to 55 Nm
11

12
High Pressure Fuel Pump –
Pre Assembly
a Check and replace the O-ring from fuel pump 13
checking that its in the correct position to avoid
damage during flange adapter assembly.
14
b Install the flange adapter to the fuel pump housing.

15

16

17

MWM INTERNATIONAL Motores

Publication P/N: 9.612.0.006.716.4 – 03/09
 Workshop Manual

Install the fuel pump gear and nut applying the Measure the clearance between both timing gears.
torque.
Clearance: 0,05 to 0.25 Nm
Torque: 100 to 110 Nm

View of assembled gears set. Clearance: 0,05 to 0.25 Nm

9-12

Place a new gasket to the front cover gear housing.

! Attention: · During the engine operation
there must not be gearing
noise.
· A noisy operation indicates
too much clearance between
gears or teeth excessive wear.

MWM INTERNATIONAL Motores

Publication P/N: 9.612.0.006.716.4 – 03/09
Workshop Manual

GEAR HOUSING

Centre the front cover with the special tool MWM nr. Place the new front seal and the special tool hub and 1
tighten as indicated placing the seal to its housing.
9.610.0.690.019.6.

Place the bolts without tightening to allow the 6

Assembly the temperature and oil pressure sensor
movement of the cover.
bolts.
Tighten the fixation bolts of the front cover.
Torque: 8,5 ± 1 Nm 7
Torque: 22 to 28 Nm

9-13

10

11

Assembly the front pulley with the damper. Tighten

Install the special tool MWM nr. 9.610.0.690.019.6. the bolts crosswise with the specified torque. 12

Tighten the 2 bolts indicated to fit the tool onto the Torque: 1st: 100 ± 10 Nm
gear. 2nd: 275 ± 15 Nm
13

14

15

16

17

MWM INTERNATIONAL Motores

Publication P/N: 9.612.0.006.716.4 – 03/09
 Workshop Manual

Assembly the adapter, then the camshaft sensor and Install the belt acessories by loosing the tightener
apply the specified torque. with a wrench.
Torque: 7.5 to 9.5 Nm

Install the pulley and tightener support.

Torque: 17 to 23 Nm

9-14

Install the fan pulley.

Torque: 34 to 46 Nm

MWM INTERNATIONAL Motores

Publication P/N: 9.612.0.006.716.4 – 03/09