CYLINDER BLOCK DISASSEMBLY (II) [WL-C, WE-C]

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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	Seal plate
3	Supply pump pulley (See Supply Pump Pulley Disassembly Note.)
4	Timing gear cover (See Timing Gear Cover Disassembly Note.)
5	Oil pump
6	Supply pump gear (See Supply Pump Gear Disassembly Note.)
7	Timing gear
8	Supply pump
9	Timing gear case (See Timing Gear Case Disassembly Note.)
10	Dual-mass flywheel (See Dual-mass flywheel Disassembly Note.)
11	End plate
12	Rear cover (See Rear Cover Disassembly Note.)
13	Seal plate
14	Oil pump cover
15	Driven gear
16	Plug
17	Plunger spring
18	Control plunger
19	Oil pump body

Crankshaft Pulley Disassembly Note

1.  Remove the crankshaft pulley using the SST.

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Supply Pump Pulley Disassembly Note

1.  Remove the supply 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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Supply 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 supply pump gear on notch back and forth, then check the chip cut gear.

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4.  Fix the scissors gear to the supply pump gear using a lock bolt (M6×1.0; length under the bolt head is approximately 16 mm {0.63 in}).

Warning

•  When removing the supply pump gear, be sure to secure the scissors gear to the supply pump gear using a lock bolt (M6×1.0; length under the bolt head is approximately 16 mm {0.63 in}). Otherwise, the scissors gear will rotate with the spring force, causing personal injury.

Caution

•  When removing the supply pump gear, be sure to secure the scissors gear to the supply pump gear using a look bolt (M6×1.0; length under the bolt head is approximately 16 mm {0.63 in}) to prevent the scissors gear form rotating with the spring force. Otherwise, the scissors gear will not align with the supply pump gear, and the supply pump gear with the scissors gear will not engage with the idler gear.

Note

•  The supply 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 supply pump gear using the SST and bolt (M6X1.0, Length 30mm {1.18 in}).

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Timing Gear Case Disassembly Note

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

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Dual-mass flywheel Disassembly Note

1.  Lock the dual-mass flywheel against rotation using the SST (49 E011 1A0).

2.  Loosen the lock bolts uniformly and gradually in the order shown in the figure, and remove them.

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•  If the lock bolt installation holes are not positioned properly, perform the following procedure:

(1)  Install the SST (205-072) and SSTs (205-072-02) or bolts M8×1.25, length 25 mm {0.98 in} to the dual-mass flywheel.

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(2)  Rotate the dual-mass flywheel (secondary flywheel side) using the SST (205-072).

(3)  When the lock bolt installation holes are positioned properly, hold the position and remove one of the lock bolts.

(4)  After removing the lock bolt, set up the proper parts and tool as shown in the figure to lock the dual-mass flywheel (secondary flywheel side) against rotation.

Warning

•  If all of the lock bolts are removed without locking the dual-mass flywheel (secondary flywheel side) against rotation, the dual-mass flywheel (primary or secondary flywheel side) may rotate, resulting in injury. Therefore, always set up the parts as shown in the figure.

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(5)  Remove the remaining lock bolts.

3.  Remove the dual-mass flywheel.

Note

•  When reusing the dual-mass flywheel, do not remove the parts and tool locking the dual-mass flywheel (secondary flywheel side) against rotation.

4.  Remove the SST.

Rear Cover Disassembly Note

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

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