Remove
Timing belt covers and timing belt – see operation "Timing Belt Remove and Install".
Nut of injection pump timing pulley – loosen only install (arrowed).
Remove
Injection pump timing pulley – use KM-6440.
Injection pump harness – for tachometer sensor throttle switch fuel cut-off solenoid.
Caution
Seal ends of injector pipes and ends of injectors injection pump unions to prevent ingress of foreign material.
Remove
Injector pipes and clips from injector nozzles and injection pump – union nuts; slacken clip bolts (arrowed).
Remove
Injection pump throttle cable fuel and vacuum hoes from fuel injection pump.
Remove
Injector pump from timing gear case – rear bracket (arrowed) and mounting nuts.
Install
Injection pump to timing gear case – align marks on timing pulley housing and injection pump tighten nuts to just hold pump.
Rear bracket (arrowed) to pump and cylinder block – tighten bolts to just hold pump.
Install
Pulley to injection pump - use locking bolt through pulley into timing gear case to hold pulley pulley nut 64 Nm.
Install
injector pipes to injectors and injection pump - loosely install place clips (arrowed) in correct position then tighten pipe union - 29 Nm.
Caution
Incorrectly positioned injector pipe clips will result in pipe breakage and fuel pulsing noise.
Install
Injection pump harness to sensors and solenoid.
Injection pump throttle cable fuel hose and hoses of cold start device.
Install
Timing belt and timing belt covers – see operation "Timing Belt Remove and Install".
Crankshaft damper pulley to hub – bolts 206 Nm.
Cooling fan to water pump – bolts 8 Nm.
Alternator and power steering pump drive belts to pulleys.
Illustration shows timing belt removed for clarity.
Adjust
Injection Pump Timing – see operation "Injection Pump Timing Check and Adjust".
Drive belts - see operation Drive Belt Tension, Check and Adjust.
