1. Before installing, make sure that the groove on the injection pump flange is aligned with the 6 mm hole on the body.
2. Insert the injection pump from the rear of the engine.
Install the injection pump bracket on the pin.
3. Tighten the injection pump mounting bolts (3 pcs.) using an extension and a TORX key.
4. Remove the sprocket holder (special tool).
5. Slowly turning the injection pump shaft with a TORX key (special tool), adjust the position of the flange, insert the mounting stop (special tool) into a hole with a diameter of 6 mm in the injection pump sprocket so that it passes through the flange into the injection pump housing.
6. Remove the TORX key (special tool).
7. Tighten the sprocket set bolts with a hex wrench (special tool, 6 mm, long).
If the injection pump sprocket washer was removed, install the washer with the front mark F towards the front of the engine.
8. Remove the installation stop (special tool).
9. Install the secondary timing chain.
Align the sprocket marks with the timing chain marks.
Note: The figure shows the secondary timing chain and related parts, as well as the names of the parts.
10. Install the timing chain guide at the tension point.
The top set bolt is longer than the bottom.
11. Install the timing chain guide at the deflection point using a hex wrench (special tool, 6 mm, short).
12. Install the chain tensioner.
Install in the following order.
- (1) Press the plunger of the chain tensioner and secure with the pin.
- (2) Tighten the set bolt with a hex wrench (special tool, 5 mm).
(3) Remove the pin securing the plunger.
Attention: Secondly check that the marks on the sprockets are aligned with the marks on the timing chain.
13. Install the front chain cover.
Install in the following order.
(1) Install the chain guide on the back of the front cover.
If you tilt the front cover, the chain guide will fall out, so keep the cover upright when installing.
(2) Apply Three Bond 1207C Sealant (KR510 00150) both ends of the oil pump (connection section from the rear cover of the chain) , as it shown on the picture.
(3) Install the front chain cover.
Align the holes in the cover with the dowel pins on the oil pump housing.
Install bolts 6, 10, 11 together with rubber washers.
(4) Tighten the set bolts in the order shown in the figure.
(5) After tightening all the bolts, re-tighten them in the order shown in the figure.
14. Install the injection pump bracket.
After tightening all the bolts, check the tightness of the surface of the injection pump and the surface of the bracket to the mounting surface, and then make the final tightening.
15. Connect the injection pump wiring connector.
Insert the connector until the latch clicks into place.
16. Connect two fuel hoses to high pressure fuel pump.
Connect the hoses according to the marks made before removal.
If the hoses were removed from the connectors, insert into the connectors and tighten the clamp tightly.
17. Complete assembly in the reverse order of removal.