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

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1.  Assemble in the order indicated in the table.

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1
Oil pump body
2
Control plunger
3
Plunger spring
4
Plug
5
Driven gear
6
Oil pump cover
(See Oil Pump Cover Assembly Note.)
7
Rear cover
(See Rear Cover, End Plate Assembly Note.)
8
End plate
(See Rear Cover, End Plate Assembly Note.)
9
Dual-mass flywheel
(See Dual-mass Flywheel Assembly Note.)
10
Seal plate
11
Timing gear case
(See Timing Gear Case Assembly Note.)
12
Supply pump
13
Timing gear
(See Timing Gear, Supply Pump Gear Assembly Note.)
14
Supply pump gear
(See Timing Gear, Supply Pump Gear Assembly Note.)
15
Oil pump
16
Timing gear cover
(See Timing Gear Cover Assembly Note.)
17
Supply pump pulley
(See Supply Pump Pulley Assembly Note.)
18
Seal plate
19
Crankshaft pulley
(See Crankshaft Pulley Assembly Note.)


Oil Pump Cover Assembly Note

1.  Tighten the bolts in two or three steps in the order shown in the figure.

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Rear Cover, End Plate Assembly Note

1.  Apply soapy water along the perimeter of the new oil seal.

2.  Push the oil seal slightly in by hand.

3.  Tap the oil seal in evenly using the SST and a hammer

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4.  To ensure that the oil seal is installed correctly, measure the distance between the end of the rear cover and the face of the oil seal.

Rear oil seal press-in amount
0—0.5 mm {0—0.01 in}

5.  Apply silicone sealant to the rear cover as shown.

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Thickness
φ2.0—3.0 mm {0.07—0.12 in}

6.  Apply silicone sealant to the rear cover as shown in the figure.

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Thickness
φ2.0—3.0 mm {0.07—0.12 in}

7.  Install the end plate.


Dual-mass Flywheel Assembly Note

1.  Clean the crankshaft thread holes.

2.  Install the dual-mass flywheel to the crankshaft.

3.  Temporarily tighten the new lock bolts.

•  If the dual-mass flywheel (secondary flywheel side) is not positioned properly, perform the following procedure to install it:
(1)  Temporarily tighten the new lock bolts to the position as shown in the figure.
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(2)  Lock the dual-mass flywheel against rotation using the SST (49 E011 1A0).
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(3)  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.
(4)  After removing the parts and tool as shown in the figure, rotate the dual-mass flywheel (secondary flywheel side) using the SST (205-072) and temporarily tighten the new lock bolt.
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4.  Lock the dual-mass flywheel against rotation using the SST (49 E011 1A0).

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5.  Tighten the lock bolts uniformly and gradually in the order shown in the figure.

Note
•  Use the SST (205-072) if the dual-mass flywheel (secondary flywheel side) is not positioned properly.
Tightening torque
151.3—161.1 N·m {15.43—16.42 kgf·m, 111.6—118.8 ft·lbf}

6.  Remove the SST.


Timing Gear Case Assembly Note

1.  Install the new O‐ring.

2.  Apply silicone sealant to the timing gear case as shown in the figure. Do not apply sealant to the O-ring.

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Thickness
φ2.0—3.0 mm {0.07—0.12 in}

3.  Tighten the bolts in two or three steps in the order shown in the figure.

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Timing Gear, Supply Pump Gear Assembly Note

1.  Put a paint mark on the chip cut gear of the supply pump gear.

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2.  Put a paint mark on the 10th and 11th teeth of the helical gear counting clockwise from the chip cut gear.

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3.  Verify that the 10th and 11th teeth of supply pump gear (helical gear) and the teeth of the scissors gear are aligned, then put a paint mark on the scissors gear.

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

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

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6.  Align the timing marks. For the supply pump gear, align the timing mark as shown in the figure (View A).

Note
•  The helical gears except for the supply pump gear have a punch mark as the timing mark. The timing mark of each gear can be aligned easily if the paint mark is made on the punch mark.
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7.  Remove the lock bolt.

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8.  Tighten the bolts using the SST.

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Timing Gear Cover Assembly Note

1.  Apply soapy water along the perimeter of the new oil seal.

2.  Push the oil seal slightly in by hand.

3.  Tap the oil seal in evenly using the SST and a hammer.

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4.  To ensure that the oil seal is installed correctly, measure the distance between the end of the timing gear cover and the face of the oil seal.

Front oil seal press-in amount
0.0—0.40 mm {0.0—0.015 in}
Fuel injection pump oil seal press-in amount
0.0—0.40 mm {0.0—0.015 in}

5.  Apply silicone sealant to the timing gear cover as shown.

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Thickness
φ2.0—3.0 mm {0.079—0.118 in}

6.  Tighten the bolts in two or three steps in the order shown in the figure.

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Supply Pump Pulley Assembly Note

1.  Install the supply pump pulley using the SST.

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Crankshaft Pulley Assembly Note

1.  Install the crankshaft pulley using the SST.

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