Diesel MFI Pump: Service and Repair

1. Remove battery and under cover.
2. Drain cooling system and disconnect upper radiator hose at engine.
3. Remove cooling fan and shroud and disconnect lower radiator hose at engine.
4. Remove air conditioner compressor, if used.
5. Remove fan belt and crankshaft pulley.
6. Remove timing pulley housing covers. Refer to ``Timing Pulley Housing Covers, Replace'' for procedure.

Fig. 18 Removing tension spring:

Fig. 19 Removing tension pulley nut:

7. Remove tension spring, Fig. 18, tension pulley nut, Fig. 19, tension center, pulley and timing belt.
8. Disconnect engine control cable and wiring harness from fuel cut-off solenoid.
9. Disconnect fuel hoses and injection pipes. Use a back-up wrench to hold delivery holder when loosening sleeve nuts on injection pump side.
10. Install a 6 mm bolt with a pitch of 1.25 into threaded hole in timing pulley to prevent pulley from turning, then remove bolts retaining injection pump timing pulley and remove pulley using suitable puller.

Fig. 33 Injection pump retaining bolts and nuts:

11. Remove injection pump flange retaining nuts and rear bracket bolts, Fig. 33, then remove injection pump.

Fig. 1 Injection pump flange to front plate alignment mark:

12. Install injection pump with marks on flange and front bracket aligned, Fig. 27.
13. Install injection pump timing pulley and torque bolt to 42-52 ft. lbs. (5.8-7.2 kg-m).

Fig. 7 TDC timing mark:

14. Rotate crankshaft until No. 1 piston is at TDC compression stroke, Fig. 7, and marks on timing pulley are aligned, Fig. 20.
15. Install timing belt. Refer to ``Timing Belt, Replace'' for procedure.
16. Check injection timing. Refer to ``Injection Timing, Adjust'' for procedure.