DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY

PW200/220-7K 30-11

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SPECIAL TOOLS

REMOVAL

1. Open up the engine hood.

2. Remove plate (1).

3. Take off radiator fan guard (2).

4. Disconnect fuel inlet hose (3) and fuel outlethose (4).★ When disconnecting the hoses, oil will flow

out. Stop the flow by inserting a wooden pluginto the hoses.

5. Disconnect tubes (5) and (6) between the fuel fil-ter and the fuel injection pump, then remove fuelfilter bracket (7).

6. Disconnect lubrication tube (8).

7. Disconnect six delivery tubes (9).

8. Detach E11 governor motor connector and thendetach governor spring (10) on the fuel injectionpump side.

REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY

Mark Part No. Part Name Necessity Qty Distinction* Sketch

A 795-799-1390 Puller ■ 1*Distinction between new and existing part.

Leave the negative (-) terminal of the battery disconnected.

1

2

3

4

7

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DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY

30-12 PW200/220-7K

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9. Adjust the timing gear to the injection timing,using timing pin (11) on the timing gear side.★ Refer to the Inspection and Adjustment of

Fuel Injection Timing Section.

10. Unscrew cap (12) to remove it.★ Use a filter wrench to unscrew the cap.

11. Remove nut (13) and washer (14) from the fuelinjection pump.

★ Be careful not to drop the nut or washerinside the case.

12. Separate the fuel injection pump shaft and drivegear, using tool A.

13. Remove two bracket mounting bolts (15) on thelower part of the fuel injection pump.

10

8

9

11

13,14

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DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY

PW200/220-7K 30-13

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14. Remove sound absorbing material (16).

15. Remove four nuts (17) to remove fuel injectionpump assembly (18).

INSTALLATION

• Install in reverse order of removal.

★ Adjust the governor lever stroke, refer to theSpecial Function of Monitor Panel section inthe INSPECTION AND ADJUSTMENTchapter, of this manual.

• Install the fuel injection pump assembly in the fol-lowing manner.1) Check that the timing pin is properly adjusted

to the fuel injection timing.★ Refer to Step 10 in the previous proce-

dure, REMOVAL.2) Remove plug (19), then reverse timing pin

(20) of the fuel injection pump and assemblethe plug to the pump again.★ Check that the cutout portion on the tim-

ing pin is engaged with protrusion ainside the pump.

★ Refer to the Inspection and Adjustmentof Fuel Injection Timing section of theTESTING AND ADJUSTING, chapter inthis manual.

3) Mount fuel injection pump assembly (18) andsecure it with four nuts (17).

Air intake hose clamp:5.4 - 6.4 Nm (0.55 - 0.65 kgm)

Hose clamp:2.84 - 3.82 Nm (0.29 - 0.39 kgm)

Joint bolt:19.6 - 29.4 Nm (2.0 - 3.0 kgm)

Sleeve nut:24 ± 4 Nm (2.45 ± 0.41 kgm)

Nut: 95 ± 10 Nm (9.7 ± 1.0 kgm)

Nut: 9.8 ± 2 Nm (1.0 ± 0.2 kgm)

20

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