FUEL INJECTION PUMP REMOVAL


  1. DRAIN ENGINE COOLANT


    1. Remove the radiator cap.

      CAUTION:

      Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    2. Check if there is any excessive deposits of rust or scale around the radiator cap and radiator filler hole. The coolant should be free from oil.

      Tech Tips

      If excessively dirty, clean the coolant passage and the coolant.

    3. Install the radiator cap.

  2. REMOVE FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)

    Tech Tips

    Use the same procedures described for the LH side. Click here

  3. REMOVE FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)

    Tech Tips

    Use the same procedures described for the LH side. Click here

  4. REMOVE FRONT DOOR SCUFF PLATE RH

  5. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Turn back the carpet, and remove the engine service hole cover sub-assembly.

  6. REMOVE RADIATOR HOSE INLET

  7. REMOVE VANE PUMP V BELT


    1. A01BCBTE01

      Loosen the bolt A and nut B, and remove the V belt.

  8. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1


    1. A01BEBYE01

      Loosen the nut A and bolt B, and remove the V belt.

  9. REMOVE FAN AND GENERATOR V BELT (w/o AIR CONDITIONING)


    1. A01BBR9E01

      Loosen the bolts A and B, and remove the V belt.

  10. REMOVE FAN AND GENERATOR V BELT (w/ AIR CONDITIONING)


    1. A01BAGHE01

      Loosen the bolts A and B.

    2. Loosen the adjusting bolt C, and remove the V belt.

  11. REMOVE FAN PULLEY


    1. Remove the 4 nuts, fan spacer and fan pulley.

  12. REMOVE COMPRESSOR AND MAGNETIC CLUTCH (w/ AIR CONDITIONING)


    1. A01BAGHE01

      Loosen the bolts A and B.

    2. Loosen the adjusting bolt C, and remove the V belt.

  13. REMOVE COMPRESSOR MOUNTING BRACKET (w/ AIR CONDITIONING)


    1. A01BDQD

      Remove the 3 bolts and compressor mounting bracket.

    2. A01BDNC

      Remove the bolt and spacer.

    3. A01BFW5

      Remove the 4 bolts and compressor mounting bracket.

  14. REMOVE VANE PUMP DRIVE PULLEY


    1. A01BG2B

      w/o Air conditioning:


      1. Remove the 4 bolts, vane pump drive pulley and the vane pump drive pulley spacer.

    2. w/ Air conditioning:


      1. Remove the 4 bolts, 2 vane pump drive pulleys.

  15. REMOVE CRANKSHAFT PULLEY


    1. A01BD00E01

      Using SST, remove the pulley bolt.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A01BDH6E01

      Using SST, remove the pulley.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )
      09950-60010   ( 09951-00490 )
      09950-40011   ( 09957-04010 )

  16. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY


    1. A01BFU5

      Remove the 11 bolts, washers, timing belt cover and 2 gaskets.

  17. REMOVE TIMING BELT GUIDE

  18. SET NO.1 CYLINDER TO TDC/COMPRESSION


    1. A01BEZ9E01

      Using the crankshaft pulley bolt, align its groove with the timing pointer by turning the crankshaft clockwise.

    2. A01BCEAE01

      Check that the timing marks of the camshaft timing pulley and No.2 timing belt cover are aligned.

      If not, turn the crankshaft 1 revolution (360°).

  19. REMOVE TIMING BELT


    1. A01BHZKE01

      Remove the timing belt.

      Tech Tips

      If reusing the timing belt, draw a direction arrow on the timing belt (in the direction of engine revolution), and place matchmarks on the pulleys and timing belt.

    2. A01BBKOE01

      Turn the crankshaft 90° counterclockwise, and put the timing mark of the crankshaft timing pulley with the protrusion of the timing gear case.

      Note

      If the timing belt is disengaged, having the crankshaft timing pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft timing pulley, causing damage. So always set the crankshaft pulley at the correct angle.

    3. A01BF04E01

      Loosen the timing belt idler No.1 bolt (A), and shift the idler to the left as far as possible.

    4. Temporarily tighten the pulley bolt (A), and then relieve the timing belt tension.

    5. Remove the timing belt.

  20. REMOVE AIR CLEANER HOSE NO.2


    1. Loosen the bolt, and disconnect the air cleaner hose No.2.

  21. REMOVE INTAKE AIR CONNECTOR SUB-ASSEMBLY


    1. Disconnect the ventilation hose.

    2. Disconnect the turbo pressure sensor connector.

    3. A01BCJN

      Remove the bolt, 3 nuts, intake air connector and gasket.

  22. REMOVE VENTURI ASSEMBLY


    1. A01BAY2E01

      Disconnect the throttle open switch connector.

    2. A01BFXZE01

      Disconnect the throttle control motor connector.

    3. Remove the venturi and gasket.

  23. REMOVE INJECTION PIPE SET


    1. Loosen the 8 union nuts of the 4 injection pipes.

    2. Remove the 2 nuts, 2 upper pipe clamps, and 4 injection pipes with lower pipe clamps.

  24. REMOVE INJECTION PUMP DRIVE PULLEY


    1. A01BEIWE01

      Using SST, remove the pulley nut.

      SST
      09213-14010   ( 91651-60865 )
      09330-00021
    2. A01BADXE01

      Using SST, remove the drive pulley.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05021 )

  25. REMOVE INJECTION OR SUPPLY PUMP ASSEMBLY


    1. Disconnect the engine speed sensor connector.

    2. Disconnect the spill control valve connector.

    3. Disconnect the correction unit connector.

    4. Disconnect the timer control valve connector.

    5. Disconnect the fuel temperature sensor connector.

    6. Disconnect the engine wire clamp.

    7. Disconnect the 3 fuel hoses.

    8. A01BBBJ

      Disconnect the 3 bolts and injection pump stay No.1.

    9. Remove the 2 nuts and injection or supply pump assembly.