Note: The following text applies to vehicles with a manual transmission and without an electronic fuel injection pump control system. References to special tool replacement and additional information are provided for models with electronic control.
Mounting pins
Manual transmission, fuel injection pump without electronic control: LRT-12-044, installed in the flywheel housing base.
Manual transmission, electronically controlled fuel injection pump: LRT-12-O85, installed in the flywheel housing base.
Automatic transmission: LRT-12-044, installed in a large hole in the engine cover next to the oil pan. The finger must enter the toothed ring of the automatic transmission drive clutch.
Removal
1. Disconnect the battery.
2. Remove the high pressure pipes from the fuel injection pump.
3. Remove the oil filler cap.
4. Bring the piston of the 1st cylinder to TDC of the compression stroke. Make sure the correct TDC is set using the cams visible through the oil filler neck.
5. Replace the oil filler cap.
6. Remove the plug from the flywheel housing base.
7. Install the LRT-12-044 pin onto the crankcase, do not engage the center pin of the pin.
8. While slightly rocking the crankshaft, insert the pin into the flywheel slot.
9. Remove the fuel injection pump drive cover from the front engine cover.
10. Insert the LRT-12-045 mounting pin into the fuel injection pump drive gear.
11. Loosen the bolts securing the gear to the pump hub. Do not unscrew the central hub nut.
12. Remove the mounting pin.
13. Install the LRT-12-045 gear lock and secure it with bolts, placing additional 2 mm washers under the bolt heads.
14. Disconnect the fuel injection pump lever cable. If equipped, disconnect the manual drive cable.
15. Disconnect the wire from the fuel shut-off valve.
16. Disconnect the fuel supply and outlet pipes, and the boost corrector pipe. Screw the tube mounting bolts back into place on the fuel injection pump.
17. Unscrew the two bolts of the rear support of the fuel injection pump.
18. Loosen the bolt securing the rear support bracket to the block so that the bracket can move.
19. Unscrew the fuel injection pump flange mounting nuts, remove the fuel injection pump and gasket.
20. Plug the fuel lines and fuel injection pump fittings.
Installation
21. Remove the plugs from the fittings.
22. Install the LRT-12-045 pin into the hub and the fuel injection pump housing.
23. Clean the mating surfaces of the fuel injection pump flange and the front engine cover.
24. Install the fuel injection pump with a new gasket, tighten the mounting nuts to a torque of 25 N·m.
25. Tighten the rear fuel pump support fasteners by hand.
26. Tighten the rear support bracket bolt to the block, then tighten the rear support bolts.
27. Connect the fuel lines, tighten the bolts to a torque of 25 N·m.
28. Connect the boost control tube and tighten the bolt to 10 Nm.
29. Connect the fuel shut-off valve wire.
30. Connect the fuel injection pump lever cables.
31. Remove pin LRT-12-045.
32. Install the drive gear retaining plate.
33. Install the LRT-12-045 pin.
34. Secure the gear to the fuel injection pump hub with three bolts.
35. Remove pin LRT-12-045.
36. Release the flywheel lock, turn the engine two revolutions, install the flywheel lock. Check the possibility of free installation of the pin into the fuel injection pump hub.
37. If the pin cannot be installed in the fuel injection pump, then:
- a) disengage the flywheel mounting pin
- b) turn the crankshaft until the pin is installed in the fuel injection pump hub
- c) loosen the fuel injection pump drive gear mounting bolts
- d) turn the crankshaft to TDC
- d) secure the flywheel with the installation pin; e) tighten the fuel injection pump drive gear mounting bolts
- g) remove the mounting pins.
38. Apply anti-seize compound to the threads of the flywheel housing base plug bolts and tighten the bolts to a torque of 12 Nm.
39. Install the fuel injection pump drive cover and tighten the bolts to a torque of 25 Nm.
40. Install the high pressure pipes, tighten the pipe nuts to a torque of 28 N·m.
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