REPLACE/REPAIR IDLER PULLEY ASSEMBLY (Continued)
Press ball bearing (17) and bushing (18) from pulley (7).
Press dowel pin (19) from pulley lever (8) and remove the pulley lever from shaft (20).
Remove yoke spring (21), washer (22), and bushing (23) from the engine side of idler pulley cover (13).
Remove seal (24) and bushing (25) from idler pulley cover (13). Discard the seal.
Do not remove studs (26) from front cover unless studs are damaged.
Death or serious injury could occur if diesel fuel oil is not handled
carefully. Use in a well-ventilated area away from open flame,
arcing equipment, ignition sources, heaters, or excessive heat.
Always store fuel in proper, marked containers. DO NOT SMOKE.
Clean all components with diesel fuel oil. Inspect for rust, corrosion, wear, or other obvious damage.
Inspect idler pulley cover and pulley lever for cracks at shaft and bushing bores, mounting flanges, and mounting
hardware bores. Discard components with cracks.
Inspect shaft, pin, and bolt (6) for wear or signs of shearing fatigue.
If the cylindrical surface of the shaft is worn significantly at any point, replace the shaft and the bushing that mates
with that surface.
Rotate ball bearing by hand, inspecting for rough or tight spots. Replace bearing if rough or tight.
Inspect ball bearing exterior for rust, corrosion, or other damage. Replace damaged bearing.
Inspect exterior surfaces of bushings for wear or scoring. Replace a worn or scored bushing.
Inspect interior diameter of bushings for excessive wear or elongation. Replace a worn or elongated bushing.
Inspect yoke spring for rust or corrosion, and loss of temper. Replace the spring if it is rusted or corroded. Replace
spring if it was not providing proper belt tension during operation.
10 Inspect the idler pulley groove for roughness, gouges, or burrs that will damage the belt. Remove burrs and smooth
gouges with a fine file. Smooth the pulley groove with crocus or emery cloth. If more than 25% of the pulley groove
requires repair, replace pulley.
11 Inspect diameter of pulley bore for distortion and elongation. Replace pulley if the internal bore is distorted.
12 Inspect stud for damaged or stripped threads. Make sure stud is not cracked, bent, or corroded. Replace damaged