FUEL INJECTION PUMP INSTALLATION


  1. INSTALL IDLE UP ACTUATOR SET (w/ A/C)


    1. w/ ACSD:

      Install the idle-up actuator.

    2. w/o ACSD:

      Using a 5 mm hexagon wrench, install the idle-up actuator with the 2 bolts.

  2. INSTALL INJECTION PUMP ASSEMBLY

    A01KGIC

    Note

    w/ HAC:

    Do not put the injection pump at an angle of more than 45° from the horizontal.


    1. Align the matchmarks of the injection pump flange and timing gear case.

    2. Install the injection pump with the 2 nuts.

      Torque:
      20.5 N*m  { 210 kgf*cm, 15 ft.*lbf }

  3. INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE

  4. INSTALL INJECTION PUMP STAY NO.1

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    1. Install the injection pump stay with the 4 bolts.

      Torque:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

  5. INSTALL INJECTION PUMP DRIVE PULLEY


    1. Using SST, install the injection pump drive pulley.

      SST
      09213-14010   ( 91651-60865 )
      09330-00021   ( 09330-00030 )

  6. INSTALL TIMING BELT

    Click here

  7. INSTALL INJECTION PIPE SET

    Click here

  8. INSTALL FUEL HOSE

  9. INSTALL FUEL HOSE NO.1

  10. INSTALL FUEL HOSE NO.2

  11. INSTALL STARTER ASSEMBLY

    Click here

  12. INSTALL ACCELERATOR LINK ASSEMBLY NO.2

  13. INSTALL THROTTLE CABLE BRACKET

  14. BLEED INJECTION PIPE


    1. Move the priming pump in the upper part of the fuel filter assembly up and down, and then fill the injection pump assembly and fuel system with fuel.

    2. Loosen one of the Flare nut (in the nozzle side).

    3. Crank the engine until the fuel comes out from the flare nut (in the nozzle side).

    4. Tighten the flare nut.

    5. The above operations should be carried out in each injection pipe.

  15. INSTALL THROTTLE CONTROL CABLE SUPPORT

  16. CONNECT CONNECTOR


    1. Connect the fuel inlet hose to the fuel inlet pipe.

    2. Connect the 2 fuel return hoses to the fuel return pipe.

    3. w/ ACSD:

      Connect the 2 water bypass hoses to the thermo wax.

    4. w/ A/C:

      Connect the vacuum hose to the idle-up actuator.

    5. Connect the accelerator link to the injection pump.

    6. w/ TCV:

      Connect the connector for the timing control valve and fuel cut solenoid.

    7. w/ TCV:

      Connect the connector for the engine speed sensor.

    8. w/o TCV:

      Connect the connector for the fuel cut solenoid and pickup sensor.

    9. w/ EGR:

      Connect the throttle position sensor connector.

  17. INSTALL INTAKE AIR CONNECTOR SUB-ASSEMBLY


    1. Using a new gasket, install the intake air connector.

  18. ADD ENGINE COOLANT

  19. INSPECT FOR FUEL LEAK

  20. CHECK ENGINE IDLE SPEED AND MAXIMUM SPEED