2/27/2019 QuickServe Online | (4021528) GTA38, K38, K50, QSK38, and QSK50 Service Manual

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Disassemble
 CAUTION 
Do not use a heating torch to remove the camshaft gear. If
a heating torch is used to remove the gear, the gear must
be replaced. The heat of the torch will damage the heat
treatment of the gear.

Use a hydraulic press to push the camshaft through the gear.

with Mechanically Actuated Injector

Camshaft keys are available in different sizes (amount of
offset). The injection timing is controlled by:
1. the selection of the camshaft key
2. the direction of the key offset when compared to the
camshaft gear rotation
3. the amount of offset.
Check and record the direction of the key offset when
compared to the camshaft gear rotation (same or opposite).
Remove the key.

with Electronically Actuated Injector

Engines with Electronically Actuated Injectors do not use offset
keys. A straight key is used.
Remove the key.

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Magnetic Crack Inspect

 CAUTION 
Use a copper braid contact that has neoprene covers to
avoid burning the teeth of the gear.

 CAUTION 
If the gear contains a keyway, position the gear so that
the keyway points toward one of the contacts.

Use a magnetic particle testing machine to check the camshaft

gear for cracks.

Use the residual method. Apply head shot amperage.

Adjust the amperage to the specified value.

Gear Outside Diameter Amperage Direct Current

Less than 101 mm [4 inch] 1000
101 mm to 203 mm [4 inch
1500
to 8 inch]
Greater than 203 mm [8
2000
inch]
Check the gear for cracks.

 CAUTION 
If the gear contains a keyway, position the gear so that
the keyway points toward the coil.

Use the residual method. Apply coil shot amperage.

Adjust the amperage to the specified value.

Gear Outside Diameter Ampere Turns

Less than 101 mm [4 inch] 4000

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Gear Outside Diameter Ampere Turns

101 mm to 203 mm [4 inch
6000
to 8 inch]
Greater than 203 mm [8
8000
inch]

Note : Ampere turn is an electrical current of one

ampere flowing through the coil, multiplied by the
number of turns in the coil.
Check the gear for cracks.

Apply dye to the gear. Surface indications will be visible to the

eye, however, below the surface indications will not. To check
for below the surface indications, use the ultraviolet light that is
part of the machine.

Do not use the gear if:

There is an open indication.
There is an indication below the surface that is in the
shaded area as shown.
There is an indication below the surface that is longer than
6 mm [0.250 inch].

There is an open indication that is in a circumferential

direction.
There is an open indication that is longer than 9.5 mm
[0.375 inch].
There is an indication below the surface that is in the
shaded area.

An indication below the surface in a radial direction is

acceptable (OK) if it is in the area that is not shaded.

 CAUTION 
The gear must be demagnetized completely and cleaned
thoroughly. Any small metal particles will cause engine
damage.

Demagnetize the gear.

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Clean and Inspect for Reuse

 WARNING 
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer's recommendations for
use. Wear goggles and protective clothing to reduce the
possibility of personal injury.

 WARNING 
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause personal
injury.

Clean the camshaft gear with solvent or steam.

Dry with compressed air.

 CAUTION 
If the area of fretting is longer than a 3 mm [0.125 inch]
wide longitudinal band, do not use the camshaft. Fretting
or other damage can result in gear movement on the
camshaft nose and can cause camshaft nose failure.

Check the camshaft nose in the gear fit area for fretting or
burrs.
If the fretting or burrs can not be removed with a fine crocus
cloth, the part must be replaced.

Measure the outside diameter.

mm in
57.201 MIN 2.2520
57.211 MAX 2.2524

 CAUTION 

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Do not use the gear if the inside diameter is damaged or

has fretting in excess of a 3 mm [0.125 inch] wide band.
Fretting or damage can result in gear movement on the
camshaft nose that can cause camshaft nose failure.

Check the camshaft gear for cracks, chipped, or broken teeth.

Check the bore of the gear for fretting or burrs.

If the fretting, burrs, or raised material can not be removed

with a fine crocus cloth, the part must be replaced.

Check the keyway of the gear for burrs. Remove burrs with a
fine crocus cloth.

If the burrs can not be removed with a fine crocus cloth, or the
keyway is damaged, the gear must be replaced.

Measure the inside diameter.

mm in
57.125 MIN 2.2490
57.150 MAX 2.2500

The part must be replaced if the inside diameter is not within

specifications.

Check the camshaft thrust bearing for damage.

Measure the thickness.

mm in
9.14 MIN 0.360
9.45 MAX 0.372

with Electronically Actuated Injector

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Inspect the backside of the camshaft gear for cracks, chipped,

or broken bosses that the cam sensor reads. The gear must
be replaced if the bosses are damaged.

Assemble
with Mechanically Actuated Injector
The camshaft gear must be removed to adjust the injection
timing. If the camshaft is replaced, do not install the camshaft
gear until the injection timing has been adjusted using a slip-fit
gear.

The following table identifies the recommended camshaft key

for each timing code.

Machining tolerances on the camshaft and the gear can cause

the injection timing not to be within specifications.

 WARNING 
Wear protective clothing to prevent personal injury from
burns.

 CAUTION 
Do not exceed the specified time or temperature. Damage
to the gear and the gear teeth will result.

 CAUTION 

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Do not attempt to install the gear without using heat.

The next steps illustrate how to install the gear on the camshaft
after the correct camshaft key is installed.

Use an oven. Adjust the temperature to 232°C [450°F]. Heat

the gear in the oven for a minimum of 1 hour to a maximum of
6 hours. The inside diameter of the gear will become larger
and will simplify the installation of the gear on the camshaft.

 WARNING 
Wear protective clothing to prevent personal injury from
burns.

 CAUTION 
Allow the air to cool the gear. Do not use water or oil to
reduce the cooling time. It will cause the gear to crack.

Use Lubriplate® Number 105, Part Number, 3163086 or

3163067, or equivalent. Lubricate the outside diameter of the
camshaft at the gear location.
The grooves in the thrust plate must be positioned toward the
camshaft gear. Install the thrust plate.
Remove the gear from the oven.

The timing mark on the camshaft gear must be visible from the
front of the camshaft after the gear is installed.

The keyway must be aligned with the key in the gear. Install
the gear.

with Electronically Actuated Injector

Install the key into the camshaft.

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The next steps illustrate how to install the gear on the camshaft
after the correct straight camshaft key is installed.

 WARNING 
Wear protective clothing to prevent personal injury from
burns.

 CAUTION 
Do not exceed the specified time or temperature. Damage
to the gear and the gear teeth will result.

 CAUTION 
Do not attempt to install the gear without using heat.

Use an oven. Adjust the temperature to 232°C [450°F]. Heat

the gear in the oven for a minimum of 1 hour to a maximum of
6 hours. The inside diameter of the gear will become larger
and will simplify the installation of the gear on the camshaft.

 WARNING 
Wear protective clothing to prevent personal injury from
burns.

 CAUTION 
Allow the air to cool the gear. Do not use water or oil to
reduce the cooling time. It will cause the gear to crack.

Use Lubriplate® Number 105, Part Number, 3163086 or

3163067, or equivalent. Lubricate the outside diameter of the
camshaft at the gear location.
The grooves in the thrust plate must be positioned toward the
camshaft gear. Install the thrust plate.

Remove the gear from the oven.

The timing mark on the camshaft gear must be visible from the
front of the camshaft after the gear is installed.

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The keyway must be aligned with the key in the gear. Install
the gear.

Last Modified: 13-Sep-2007

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