FUEL INJECTION PUMP REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

  2. DRAIN ENGINE COOLANT

    Note

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


    1. A01DWSH

      Remove the reservoir cap and, using a wrench, remove the vent plug.

    2. Loosen the cylinder block drain cock plug and the radiator drain cock plug and then drain the coolant.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

      A01DZFLE01

  3. REMOVE RADIATOR HOSE INLET

  4. REMOVE VANE PUMP V BELT


    1. A01DXYIE01

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

  5. REMOVE COOLER COMPRESSOR V BELT (w/ Air Conditioning System)


    1. A01DZBJE01

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

  6. REMOVE FAN AND GENERATOR V BELT (w/o Air Conditioning System)


    1. A01E2DLE01

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

  7. REMOVE FAN AND GENERATOR V BELT (w/ Air Conditioning System)


    1. A01DVWPE01

      Loosen the bolts A and B.

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

  8. REMOVE FAN SHROUD


    1. A01DWF7

      Remove the 3 bolts and oil reservoir.

    2. Disconnect the No. 1 and No. 2 water by-pass hoses from the tank upper and lower.

    3. Remove the bolt and radiator reservoir.

    4. Loosen the 4 nuts holding the fluid coupling fan.

    5. Remove the vane pump V belt, cooler compressor V belt and fan and generator V belt Click here.

    6. Remove the 2 bolts holding the fan shroud.

    7. Remove the 4 nuts of the fluid coupling fan, and then remove the shroud together with the coupling fan.

      Note

      Be careful not to damage the radiator core.

    8. Remove the fan pulley from the water pump.

  9. REMOVE FAN PULLEY

  10. DISCONNECT COOLER COMPRESSOR (w/ Air Conditioning System)


    1. A01DVYG

      Remove the 4 bolts and disconnect the cooler compressor.

      Tech Tips

      It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

  11. REMOVE COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)


    1. A01E1CQE01

      Remove the bolt and spacer.

    2. A01DXAJE01

      Remove the 4 bolts and compressor mounting bracket.

  12. REMOVE VANE PUMP DRIVE PULLEY

    A01E07R

    1. w/o Air conditioning:

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

    2. w/ Air conditioning:

      Remove the 4 bolts and vane pump drive and No. 2 crankshaft pulleys.

  13. REMOVE CRANKSHAFT PULLEY

    A01E0ECE01

    1. Using SST, remove the pulley bolt.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A01E072E01

      Using SST, remove the pulley.

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

  14. REMOVE TIMING BELT COVER


    1. A01DWFG

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

  15. REMOVE TIMING BELT GUIDE


    1. Remove the timing belt guide.

  16. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01E10G

      Turn the crankshaft pulley and align its groove with the timing pointer.

    2. Check that the valve lifters on the No. 1 cylinder are loose and valve lifters on the No. 4 are tight.

      If not, turn the crankshaft one revolution (360°) and align the mark as above.

  17. REMOVE TIMING BELT


    1. A01DZPNE01

      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. A01E0N0E02

      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. A01E2U1E01

      Loosen the No. 1 timing belt idler 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.

  18. REMOVE AIR CLEANER HOSE


    1. Disconnect the IAT sensor connector.

    2. Detach the clamp of the IAT sensor harness.

    3. Loosen the 2 clamps from the air cleaner hose.

    4. Remove the air cleaner hose.

  19. REMOVE INTAKE PIPE ASSEMBLY


    1. A01DZM6

      Remove the 2 bolts and loosen the hose clamp.

  20. REMOVE VENTURI


    1. A01DWS5E02

      Disconnect the throttle open switch connector.

    2. A01E2GDE02

      Disconnect the throttle control motor connector.

    3. Remove the venturi and gasket.

  21. REMOVE INJECTION PIPE SET


    1. A01DX04

      Using a union nut wrench, 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.

  22. REMOVE INJECTION PUMP DRIVE PULLEY


    1. A01E2RTE01

      Using SST, remove the pulley nut.

      SST
      09213-14010   ( 91651-60865 )
      09330-00021
    2. A01DWADE01

      Using SST, remove the drive pulley.

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

  23. REMOVE INJECTION PUMP ASSEMBLY


    1. A01DZZ2E01

      Disconnect the engine speed sensor connector.

    2. Disconnect the spill control valve connector.

    3. Disconnect the correction unit connector.

    4. Disconnect the timing control valve connector.

    5. Disconnect the fuel temperature sensor connector.

    6. Disconnect the engine wire clamp.

    7. Disconnect the 3 fuel hoses.

    8. A01E2K6E01

      Remove the 3 bolts and injection pump stay.

    9. Remove the 2 nuts and injection pump.