When replacing the parts in the following chart (A), replace the No. 1 injection pipe subassembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.
|Replaced Parts (A)||Pipes Requiring New Replacement|
After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.
The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or dropped.
Make sure foreign matter does not enter the fuel path.
INSTALL SUPPLY PUMP ASSEMBLY
Do not hold the supply pump assembly by the parts indicated by the arrows in the illustration.
With SST set, do not turn the crankshaft more than a half rotation.
Apply a light coat of engine oil to a new O-ring.
Install the O-ring to the supply pump assembly.
|*a||Supply Pump Shaft Key|
To insert the supply pump assembly shaft in the supply pump shaft sprocket, it may be necessary to turn the supply pump assembly several degrees and the groove in the supply pump assembly shaft are aligned.
When installing a new supply pump assembly, adjust the supply pump assembly injection pump drive shaft key assignment by turning the supply pump assembly shown in the illustration.
Using SST, tighten clockwise direction the supply pump assembly, and then temporarily install the 3 fuel supply pump fixing nuts.
Using SST, tighten and insert the supply pump assembly up to the position shown in the illustration and tighten the 3 fuel supply pump fixing nuts.
After tightening the part with SST, a gap of 2 to 3 mm in area A shown in the illustration is normal.
Install the No. 1 fuel pump bracket with the 2 bolts to the supply pump assembly and cylinder block sub-assembly.
Remove SST and the 3 set bolts.
Using SST, hold the crankshaft pulley subassembly and tighten the set nut.
INSTALL TIMING CHAIN COVER PLATE
Install the timing chain cover plate and new gasket with the 3 bolts.
INSTALL FUEL PUMP MOTOR WIRE
Attach the clamp and install the fuel pump motor wire.
Connect the fuel pump motor wire connector.
INSTALL FUEL INJECTION PUMP COVER SUB-ASSEMBLY
Install the fuel injection pump cover sub-assembly to the supply pump assembly.
INSTALL NO. 1 FUEL HOSE
Install the No. 1 fuel hose to the supply pump assembly and No. 2 fuel pipe, and slide the 2 clamps to secure it.
INSTALL NO. 2 FUEL HOSE
Install the No. 2 fuel hose to the supply pump assembly and No. 3 nozzle leakage pipe assembly, and slide the 2 clamps to secure it.
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
CONNECT NO. 3 ENGINE WIRE (for Cold Area Specification Vehicles)
INSTALL FAN SHROUD
INSTALL RADIATOR RESERVOIR ASSEMBLY
INSTALL NO. 1 RADIATOR HOSE
INSTALL NO. 2 INTERCOOLER AIR HOSE
INSTALL INTERCOOLER AIR HOSE
INSTALL INTAKE MANIFOLD
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
BLEED AIR FROM FUEL SYSTEM
INSPECT FOR FUEL LEAK
INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY