REMOVAL AND INSTALLATION


Pre-removal Operation
  • Battery and Battery Tray Removal (Refer to GROUP 54A - Battery ).
  • Fuel Injection Pipe Assembly Removal (Refer to ).

 Post-installation Operation
  • Fuel Injection Pipe Assembly Installation (Refer to ).
  • Battery and Battery Tray Installation (Refer to GROUP 54A - Battery ).
  • Fuel Line Air-bleeding (Refer to ).
  • Accelerator Cable Adjustment (Refer to GROUP 17 - Engine Control, On-vehicle Service, Accelerator Cable Check and Adjustment ).
  • Injection Timing Adjustment (Refer to GROUP 11E - On-vehicle Service, Injection Timing Check and Adjustment ).




Removal steps
<<A>>
·
 Set No.1 cylinder to TDC of its compression stroke (Removal only).


1.
 Control wiring harness connector


2.
 Accelerator cable connection


3.
 Boost hose connection


4.
 Fuel feed hose connection


5.
 Fuel feed hose connection


6.
 Fuel return hose


7.
 Power steering oil pump bolt


8.
 Vacuum pump bolt

>>A<<
 9.
 Fuel injection pump, flange plate and fuel injection pump gear assembly


10.
 O-ring


11.
 Fuel injection pump stay

REMOVAL SERVICE POINT

<<A>> SET NO.1 CYLINDER TO TDC OF ITS COMPRESSION STROKE.
caution Never turn the crankshaft anti-clockwise.

Turn the crankshaft clockwise, align each timing mark to set No.1 cylinder to TDC (top dead centre) of its compression stroke.

INSTALLATION SERVICE POINT

>>A<< FUEL INJECTION PUMP, FLANGE PLATE AND FUEL INJECTION PUMP GEAR ASSEMBLY INSTALLATION

Turn the crankshaft clockwise, align each timing mark to set No.1 cylinder to TDC (top dead centre) of its compression stroke.

1.Install the front plate after mating marks on the fuel injection pump gear and the flange plate so that the fuel injection pump gear cannot be rotated. It’s installed in front plate so that fuel injection pump gear doesn’t revolve together with a match mark of fuel injection pump gear and flange plate.