Removal Procedure
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
Fuel/gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
Wear safety glasses in order to avoid eye damage.
Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution .
- Relieve the fuel system pressure. Fuel Pressure Relief
- Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection (Without KL9) , or Battery Negative Cable Disconnection and Connection (With KL9)
Use the crankshaft balancer absorber bolt (1) to turn the crankshaft balancer absorber until the markings (2, 3) line up. Ensure cylinder 1 is at top dead cylinder (TDC) of the combustion stroke.
Extend the TDC marking (1).
Turn the crankshaft balancer absorber in the direction of engine rotation to 80 degrees (a) after TDC using the crankshaft balancer absorber bolt (1).
Remove the fuel injection pump sound insulator (1). Fuel Injection Pump Sound Insulator Replacement
Disconnect the fuel feed front pipe (1) from the fuel injection pump. Fuel Feed Front Pipe Replacement
- NOTE:
High pressure fuel feed pipes are one time use only. ALWAYS install a NEW high pressure fuel feed pipe if the pipe is removed OR the fittings are loosened.
Remove and DISCARD the fuel injection fuel feed front pipe (1). Fuel Injection Fuel Feed Front Pipe Replacement
- CAUTION:
Alternately loosen the fuel pump bolts one turn at a time until the pump is fully disengaged from fuel pump lifter follower. Trying to remove the pump bolts without even side-to-side loosening may result in pump plunger damage
Remove the fuel injection pump bolts (1).
- Remove the fuel injection pump (2).
- The fuel injection pump shaft lifter roller MAY remain in the cylinder head bore after removing the fuel injection pump.
- If the fuel injection pump shaft lifter roller does NOT pull out of the cylinder head bore with the fuel injection pump, then remove it afterwards.
- Remove the fuel injection pump shaft lifter roller (3).
Remove and DISCARD the fuel injection pump housing seal (1).
Ensure that during removal of the fuel injection pump that the fuel injection pump shaft lifter roller does NOT fall apart.