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.

Mount the injection pump on SST.

• SST
• 09241-76022
  09245-54010

Remove the overflow screw, nozzle leakage pipe and 2 washers.

Remove the bolt and wiring bracket.

Remove the cap nut, fuel pipe and 2 washers.

Remove the fuel inlet hollow screw and washer.

Using a 5 mm hexagon wrench, remove the 2 bolts and timing control valve.

Using SST, remove the distributive head plug.

• SST
• 09260-54012(09262-54010)

Remove the O-ring.

Using SST, remove the 4 delivery valve holders and 4 springs.

• SST
• 09260-54012(09269-54020)

Remove the 4 delivery valves and 4 gaskets.

• УКАЗАНИЕ:

• Arrange the delivery valves, springs and holders in the order they were removed.

• ПРИМЕЧАНИЕ:

• Do not touch the sliding surfaces of the delivery valve with your hand.

Remove the timing belt (See page ).

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.

Using SST, remove the pulley nut.

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

Using SST, remove the drive pulley.

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

Disconnect the 5 connectors and detach the wire harness clamp.

Disconnect the 3 fuel hoses.

Remove the 3 bolts and injection pump stay.

Remove the 2 nuts and injection pump.

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.

Check the fuel filter multi-information display.

• ПРИМЕЧАНИЕ:

• When the fuel system warning is displayed on the multi-information display, replace the fuel filter (See page ) or drain the water in the fuel filter.

Disconnect the level warning switch connector.

Remove the 2 nuts and lift up the fuel filter.

Connect a hose to the fuel filter drain plug. Place the other end of the hose into a container under the fuel filter drain plug.

Loosen the fuel filter drain plug to drain water.

Tighten the fuel filter drain plug by hand.

• ПРИМЕЧАНИЕ:

• Do not use any tools in this procedure.

Install the fuel filter with the 2 nuts.

• Момент затяжки:
• 18 N*m{ 184 kgf*cm, 13 ft.*lbf}

Connect the level warning switch connector.