CYLINDER BLOCK DISASSEMBLY (II) [WLT-1, WLT-2, WL-3]

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1.  Disassemble in the order shown in the figure.

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1
Crankshaft pulley
(See Crankshaft Pulley Disassembly Note.)
2
Fuel injection pump pulley
(See Fuel Injection Pump Pulley Disassembly Note.)
3
Timing gear cover
(See Timing Gear Cover Disassembly Note.)
4
Oil pump
5
Fuel injection pump gear
(See Fuel Injection Pump Gear Disassembly Note.)
6
Timing gear
7
Fuel injection pump
8
Timing gear case
(See Timing Gear Case Disassembly Note.)
9
Flywheel
(See Flywheel Disassembly Note.)
10
End plate
11
Rear cover
(See Rear Cover Disassembly Note.)
12
Oil pump cover
13
Driven gear
14
Plug
15
Plunger spring
16
Control plunger
17
Oil pump body


Crankshaft Pulley Disassembly Note

1.  Remove the crankshaft pulley using the SST.

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Caution
•  The CKP sensor plate is a very important part for engine operation control; any deformation of the plate may disable the operation control.
When disassembling/assembling the crankshaft pulley, be very careful not to deform the plate by interference with other parts or improper handling.
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Fuel Injection Pump Pulley Disassembly Note

1.  Remove the fuel injection pump pulley using the SST.

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Timing Gear Cover Disassembly Note

1.  Remove the timing gear cover using a separator tool.

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2.  Remove the oil seal using a screwdriver protected with a rag.

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Fuel Injection Pump Gear Disassembly Note

1.  Set the No.1 cylinder to TDC of compression.

2.  Rotate the flywheel ring gear from TDC to approximately 30° BTDC (about 13 teeth on the gear).

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3.  Verify that the end-gap (V groove) of the timing gear case and the chip cut gear of the fuel injection pump gear are aligned.

Note
•  If the chip cut gear is hard to find, move the fuel injection pump gear on notch back and forth, then check the chip cut gear.
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4.  Fix the scissors gear to the fuel injection pump gear using a lock bolt (M8×1.25; length under the bolt head is approximately 14 mm {0.55 in}).

Warning
•  When removing the fuel injection pump gear, be sure to secure the scissors gear to the fuel injection pump gear using a lock bolt (M8×1.25; length under the bolt head is approximately 14 mm {0.55 in}). Otherwise, the scissors gear will rotate with the spring force, causing personal injury.
Caution
•  When removing the fuel injection pump gear, be sure to secure the scissors gear to the fuel injection pump gear using a look bolt (M8×1.25; length under the bolt head is approximately 14 mm {0.55 in}) to prevent the scissors gear form rotating with the spring force. Otherwise, the scissors gear will not align with the fuel injection pump gear, and the fuel injection pump gear with the scissors gear will not engage with the idler gear.
Note
•  The fuel injection pump gear with a scissors gear has a lock bolt hole.
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5.  Hold the crankshaft using the SST and loosen the gear nut.

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6.  Remove the fuel injection pump gear using the SST.

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Timing Gear Case Disassembly Note

1.  Remove the timing gear case using the separator tool.

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Flywheel Disassembly Note

1.  Remove the flywheel using the SST.

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Rear Cover Disassembly Note

1.  Remove the oil seal using a screwdriver protected with a rag.

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