Install 4 new injection nozzle seat gaskets and the 4 injection nozzle seats to the injection nozzle holes of the cylinder head.

Using SST, install the 4 nozzle holder and nozzle sets.

• SST
• 09268-64010(09268-64020)

• Момент затяжки:
• 64 N*m{ 650 kgf*cm, 47 ft.*lbf}

Install 4 new ring packing washers and the leakage pipe with the 4 nuts.

• Момент затяжки:
• 30 N*m{ 301 kgf*cm, 22 ft.*lbf}

Connect the fuel hose to the leakage pipe.

Install the No. 1 glow plug resistor insulator and No. 1 glow plug connector.

Install the glow plug connector with the 4 nuts. Uniformly tighten the nuts.

• Момент затяжки:
• 1.0 N*m{ 10 kgf*cm, 9 in.*lbf}

Install the 4 screw grommets.

Connect the engine wire and install the No. 2 glow plug resistor insulator and washer with the bolt.

• Момент затяжки:
• 5.0 N*m{ 51 kgf*cm, 44 in.*lbf}

Install the 2 lower clamps to the intake manifold.

Install the 4 injection pipes.

• Момент затяжки:
• 25 N*m{ 250 kgf*cm, 18 ft.*lbf}

• ПРИМЕЧАНИЕ:

• Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (See page ).

Install the 2 upper pipe clamps with the 2 nuts.

• Момент затяжки:
• 5.0 N*m{ 51 kgf*cm, 44 in.*lbf}

Install the diesel throttle body (See page ).

Move the hand pump on the upper part of the fuel filter up and down and fill the injection pump and fuel system with fuel.

Loosen one of the union nuts (on the nozzle side).

Crank the engine until fuel comes out from the union nut connection (on the nozzle side).

Tighten the union nut.

• Момент затяжки:
• 25 N*m{ 250 kgf*cm, 18 ft.*lbf}

• ПРИМЕЧАНИЕ:

• Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (See page ).

Perform the procedures above for each injection pipe.

Check that there are no fuel leaks anywhere in the fuel system after performing maintenance.

• УКАЗАНИЕ:

• When checking for fuel leaks, make sure that there is pressure in the fuel line.

Install the pressure pin, distance piece and nozzle assembly to the nozzle retaining nut.

Install the nozzle holder pressure spring and adjusting shim, and then temporarily install the nozzle holder to the nozzle retaining nut.

Using SST, tighten the nozzle retaining nut.

• SST
• 09268-64010(09268-64020,09268-64030)

• Момент затяжки:
• 47 N*m{ 475 kgf*cm, 34 ft.*lbf}

• ПРИМЕЧАНИЕ:

• Overtightening could cause nozzle deformation and needle adhesion or other defects.

Inspect the holder and nozzle set.

Install a new washer and the ring packing setting nut.

Pressure test:

Install the nozzle holder to an injection nozzle hand tester and bleed air from the union nut connection.

• ПРЕДОСТЕРЕЖЕНИЕ:

• Do not place your finger on the nozzle injection hole.

Pump the tester handle a few times as fast as possible to discharge the carbon from the injection hole.

Pump the tester handle slowly and observe the pressure gauge.

Read the pressure gauge just as the injection pressure begins to drop.

• Standard pressure:
• 15790 to 16570 kPa (161.0 to 169.0 kgf/cm², 2290 to 2403 psi)

• УКАЗАНИЕ:

It can be concluded that the nozzle is operating properly when a swishing sound is heard.

If the pressure is not within the standard, disassemble the nozzle holder and replace only the shim on the top of the pressure spring. Varying the adjusting shim thickness by 0.005 mm (0.000197 in.) changes the injection pressure by approximately 628 kPa (6.4 kgf/cm², 91 psi).

• Standard Adjusting Shim Thickness:

• Specified Condition
  0.900 mm (0.0354 in.)	1.300 mm (0.0512 in.)	1.700 mm (0.0669 in.)
  0.950 mm (0.0374 in.)	1.350 mm (0.0531 in.)	1.750 mm (0.0709 in.)
  1.000 mm (0.0394 in.)	1.400 mm (0.0551 in.)	1.800 mm (0.0728 in.)
  1.050 mm (0.0413 in.)	1.450 mm (0.0571 in.)	1.850 mm (0.0728 in.)
  1.100 mm (0.0433 in.)	1.500 mm (0.0591 in.)	1.900 mm (0.0748 in.)
  1.150 mm (0.0453 in.)	1.550 mm (0.0610 in.)	1.950 mm (0.0768 in.)
  1.200 mm (0.0472 in.)	1.600 mm (0.0630 in.)	-
  1.250 mm (0.0492 in.)	1.650 mm (0.0650 in.)	-

Leakage test:

Spray pattern test:

Using a wooden stick and brass brush, clean the nozzle.

• ПРИМЕЧАНИЕ:

• Do not touch the nozzle contact surface with your fingers.

Using a wooden stick, remove the carbon adhering to the nozzle needle tip.

Text in Illustration

*1	Wooden Stick

Using a brass brush, remove the carbon from the exterior of the nozzle body (except lapped surface).

Wash the nozzle in clean diesel fuel.

• ПРИМЕЧАНИЕ:

• Do not touch the nozzle contact surfaces with your fingers.

Perform the following test several times, rotating the needle slightly each time.

Remove the ring packing setting nut and washer.

Using SST, remove the nozzle retaining nut.

• SST
• 09268-64010(09268-64020,09268-64030)

• ПРИМЕЧАНИЕ:

• Be careful not to drop the inner parts.

Remove the diesel throttle body (See page ).

Using a union nut wrench, loosen the 8 union nuts of the 4 injection pipes.

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

Remove the nut, No. 2 glow plug resistor insulator and washer and disconnect the wire harness.

Remove the 4 screw grommets and 4 nuts.

Remove the No. 1 glow plug connector and No. 1 glow plug resistor insulator.

Disconnect the fuel hose from the leakage pipe.

Remove the 4 nuts, leakage pipe and 4 ring packing washers.

Using SST, remove the 4 injection nozzles, 4 injection nozzle seats and 4 injection nozzle seat gaskets.

• SST
• 09268-64010(09268-64020)

Temporarily install the injection pump to the timing gear case with the 2 nuts.

Temporarily install the injection pump stay to the injection pump rear end with the 3 bolts.

Rotate the pump body to align the marks on the pump flange and timing gear case.

Tighten the 2 nuts.

• Момент затяжки:
• 21 N*m{ 209 kgf*cm, 15 ft.*lbf}

Tighten the 3 bolts.

• Момент затяжки:
• 26 N*m{ 265 kgf*cm, 19 ft.*lbf}

Connect the 3 fuel hoses.

Connect the 5 connectors and attach the wire harness clamp.

Using SST, install the injection pump drive pulley with the nut.

• SST
• 09213-14010(91651-60865)
  09330-00021

• Момент затяжки:
• 64 N*m{ 650 kgf*cm, 47 ft.*lbf}

Install the 2 lower clamps to the intake manifold.

Install the 4 injection pipes.

• Момент затяжки:
• 25 N*m{ 250 kgf*cm, 18 ft.*lbf}

• ПРИМЕЧАНИЕ:

• Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (See page ).

Install the 2 upper pipe clamps with the 2 nuts.

• Момент затяжки:
• 5.0 N*m{ 51 kgf*cm, 44 in.*lbf}

Install the diesel throttle body (See page ).

Install the timing belt (See page ).

Move the hand pump on the upper part of the fuel filter up and down and fill the injection pump and fuel system with fuel.

Loosen one of the union nuts (on the nozzle side).

Crank the engine until fuel comes out from the union nut connection (on the nozzle side).

Tighten the union nut.

• Момент затяжки:
• 25 N*m{ 250 kgf*cm, 18 ft.*lbf}

• ПРИМЕЧАНИЕ:

• Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (See page ).

Perform the procedures above for each injection pipe.

Install 4 new gaskets and the 4 valves to the distributive head.

Install the 4 springs to the 4 delivery valve holders.

Using SST, install the delivery holders.

• SST
• 09260-54012(09269-54020)

• Момент затяжки:
• 59 N*m{ 600 kgf*cm, 43 ft.*lbf}

Install a new O-ring to the distributive head plug.

Using SST, install the head plug.

• SST
• 09260-54012(09262-54010)

• Момент затяжки:
• 88 N*m{ 900 kgf*cm, 65 ft.*lbf}

Using a 5 mm hexagon wrench, install the timing control valve with the 2 bolts.

Install a new washer and the hollow screw.

• Момент затяжки:
• 37 N*m{ 375 kgf*cm, 27 ft.*lbf}

Install 2 new washers and the fuel pipe with the cap nut.

• Момент затяжки:
• 27 N*m{ 271 kgf*cm, 20 ft.*lbf}

Install the wiring bracket with the bolt.

• Момент затяжки:
• 8.0 N*m{ 82 kgf*cm, 71 in.*lbf}

Install 2 new washers and the nozzle leakage pipe with the overflow screw.

• Момент затяжки:
• 27 N*m{ 271 kgf*cm, 20 ft.*lbf}

Inspect the engine speed sensor.

Measure the resistance according to the value(s) in the table below.

• Standard Resistance:

• Tester Connection	Condition	Specified Condition
  1 (NE-) - 2 (NE+)	20°C (68°F)	205 to 255 Ω

If the result is not as specified, replace the injection pump assembly.

Inspect the spill control valve.

Measure the resistance according to the value(s) in the table below.

• Standard Resistance:

• Tester Connection	Condition	Specified Condition
  1 (SPV-) - 2 (SPV+)	20°C (68°F)	1 to 2 Ω

If the result is not as specified, replace the injection pump assembly.

Inspect the fuel temperature sensor.

Measure the resistance according to the value(s) in the table below.

• Standard Resistance:

• Tester Connection	Condition	Specified Condition
  1 (E2) - 2 (THF)	20°C (68°F)	2.21 to 2.69 kΩ

• ПРИМЕЧАНИЕ:

• When checking the sensor in water, be careful not to allow water to contact the terminals. After checking, wipe the water off the sensor.

If the result is not as specified, replace the injection pump assembly.

Inspect the timing control valve.

Measure the resistance according to the value(s) in the table below.

• Standard Resistance:

• Tester Connection	Condition	Specified Condition
  1 (+B) - 2 (TCV)	20°C (68°F)	10 to 14 Ω

If the result is not as specified, replace the timing control valve.

Inspect the timing control valve operation.

• ПРИМЕЧАНИЕ:

Connect the positive (+) lead of the battery to the timing control valve +B terminal.

Connect the negative (-) lead of the battery to the timing control valve TCV terminal.

Check that the solenoid makes a "click" sound.

If the result is not as specified, replace the timing control valve.

Pull up the valve and release it. Check that it sinks smoothly into the valve seat. If the operation is not as specified, replace the valve and valve seat as a set.

• УКАЗАНИЕ:

• Before using a new valve set, wash off the rust prevention compound with diesel fuel. Then rewash with diesel fuel and perform the above test.