1G
Injection Pump Removal and Installation
NOTE:
After replacing injection pump, preform Initialization Procedure for the High Pressure Pump Data:K9K .
Removal
1) Check that engine is cold and fuel pressure is not under pressure referring to Fuel Pressure Relief Confirmation Procedure:K9K .
2) Disconnect negative (–) cable at battery.
3) Remove timing belt referring to Timing Belt and Belt Tensioner Removal and Installation:K9K .
4) Disconnect connectors from fuel flow actuator (1) and fuel temperature sensor (2).
5) Disconnect fuel feed hose (3) and fuel return hoses (4) from injection pump.
6) Remove high pressure pipe (5) referring to High Pressure Pipes Removal and Installation:K9K .
7) Remove injection pump pulley (1) as follows, if necessary.
a) Remove injection pump pulley nut.
b) Remove injection pump pulley using puller (2).
CAUTION:
Be sure to apply claws of puller to the specified positions on pulley indicated in the figure. Applying to the other positions may break pulley.
8) Plug all joint part of disconnected fuel injection circuit with cap available as a spare part to prevent them from entering dust. (Refer to “Precaution” under Fuel Delivery System Description:K9K for parts number and handling.)
9) Remove injection pump (1) from cylinder head by removing 3 bolts (2).
Installation
Reverse removal procedure for installation noting the following.
• Tighten injection pump bolts to specified torque.
Tightening torque
Injection pump bolt ( a ): 27 N·m ( 2.7 kg-m, 19.5 lb-ft)
• Install injection pump pulley (4) to injection pump (2) aligning key (3) to groove (1).
• Tighten injection pulley nut to specified torque.
Tightening torque
Injection pump pulley nut ( a ): 15 N·m (1.5 kgf-m, 11.0 lbf-ft) and 60° by the specified procedure
• Install new high pressure pipe referring to High Pressure Pipes Removal and Installation:K9K .
• Install timing belt referring to Timing Belt and Belt Tensioner Removal and Installation:K9K .
• Check fuel leakage referring to Fuel Leakage Check:K9K .
• Perform Initialization Procedure for the High Pressure Pump Data:K9K .