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15°±1°after TDC Fuel Injection Pump Timing Test (DE-04.07) This test is divided into the following sections A. Static RIV Method B. Dynamic RIV Method A. Static REV Method Test Data RI-Test value (Indirect delivery begin) Tightening Torque RI-Test connection plug 30-35 Nm (22-25 ft lb) B. Dynamic RIV Method Test Data RI-Test value (Indirect delivery begin) Equipment Engine analyzer Bear DACE (Model 40-960); SUN EMT-1019/Master 3; SUN MCM-2110; SUN MEA -1500 MB

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1. Remove the timing belt. For additional information, refer to Section 303-01A Engine / 303-01B Engine. 2. Detach the air conditioning (A/C) compressor and secure it to one side. 3. Remove the A/C compressor retaining bracket. 4. Remove the components in the order indicated in the following illustration(s) and table(s). Item Part Number 1 – Generator electrical connector retaining nut 2 – Battery positive cable 3 – Generator electrical connector 4 Special tool (303 193) 21-104 See Removal Detail See Installation Detail Generator retaining bolts Generator Generator bracket retaining nut Generator bracket retaining bolts Generator retaining bracket Description 10 – Fuel injection pump support bracket retaining bolts 11 – High-pressure fuel injection pipe to fuel injector unions See Removal Detail See Installation Detail 12 – High-pressure fuel injection pipe to fuel injection pump unions 13 – High-pressure fuel injection pipes See Removal Detail See Installation Detail 14 – High-pressure fuel injection pipe to fuel injector unions See Installation Detail 15 – High-pressure fuel injection pipe to fuel injection pump unions 16 – High-pressure fuel injection pipes See Removal Detail See Installation Detail 17 – Fuel injection pump supply line See Removal Detail 18 – Fuel injection pump return line See Removal Detail See Installation Detail 19 – Fuel injection pump electrical connector 20 – Fuel injection pump support bracket retaining bolts 21 – Fuel injection pump support bracket

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Warning: Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”. 1. Remove the following parts. (1) Plug hole plate (2) Plug hole plate bracket (3) Accelerator cable and bracket (4) Battery cover 2. Disconnect the negative battery cable. 3. Remove the following parts. (1) Ignition coils (2) Front wheel and tire (RH) (3) Under cover and splash shields (4) Crankshaft position (CKP) sensor (5) Drive belt (6) A/C compressor with the oil hose still connected and position the A/C compressor so that it is out of the way (7) Coolant reserve tank with the hose still connected and position the coolant reserve tank so that it is out of the way 4. 5. 6. 7. Remove in the order indicated in the table. Install in the reverse order of removal. Start the engine. Inspect the following and adjust if necessary. Pulley and belt for runout and contact Leakage of engine oil Ignition timing, idle speed, and amount of CO and HC (See ENGINE TUNE-UP [LF, L3].) See: Tune-up and Engine Performance Checks\Testing and Inspection Engine-driven accessories operation Crankshaft Pulley Lock Bolt Removal Note 1. Remove the cylinder block lower blind plug. 2. Install the SST.

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Removal 1. Release fuel pressure. See FUEL PRESSURE RELEASE under REMOVAL & INSTALLATION. Disconnect negative battery cable. Drain coolant from radiator and cylinder block. Remove radiator shroud and fan. Remove accessory drive belts. Remove spark plugs. 2. Remove distributor cap. Set cylinder No. 1 at TDC of compression stroke (rotate crankshaft until marks on crankshaft pulley and front cover align, and distributor rotor points to spark plug wire No. 1 on cap). Remove distributor. Remove power steering pump, idler pulley and power steering pump brackets. 3. Remove A/C compressor idler pulley (if equipped). Remove crankshaft pulley. Remove oil pump and oil pump drive spindle from right side of front cover. Remove oil pan. See OIL PAN under REMOVAL & INSTALLATION. Remove front cover. 4. Remove chain tensioner, chain guides, timing chain and sprocket. Remove oil thrower, oil pump drive gear and crankshaft sprocket. Inspection Check chain roller links. Replace chain if roller links are cracked or worn. Installation 1. Install crankshaft sprocket with sprocket teeth toward front of engine, and shoulder toward rear of engine. Install oil pump drive gear with gear teeth toward front of engine, and shoulder toward rear of engine. Install oil thrower. 2. Ensure cylinder No. 1 is at TDC of compression stroke. Camshaft knockpin (or keyway) and crankshaft sprocket keyway should be at 12 o’clock position. See Fig. 7 . Install timing chain, aligning timing chain links with timing mark on each sprocket. 3. Tighten camshaft sprocket bolt to specification. See TORQUE SPECIFICATIONS . Install chain guide. Install chain tensioner. Apply lithium grease to sealing lip of front cover oil seal. Apply a .08-.12″ (2-3 mm) diameter bead of sealant to front cover. 4. Install front cover, ensuring front cover-to-cylinder block oil seals are in position on right sealing surface of cylinder block. Apply sealant to rubber plugs for cylinder head cover. See Fig. 4 . Install rubber plugs. Install cylinder head cover. Tighten bolts to specification. 5. Install oil pan. See OIL PAN under REMOVAL & INSTALLATION. Align punch mark on oil pump drive spindle with oil hole on oil pump. See Fig. 8 . Using NEW gasket, install oil pump and drive spindle assembly into front cover. Ensure upper end of drive spindle is correctly positioned. Install distributor, ensuring rotor is correctly positioned. To complete installation, reverse removal procedure.

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1. Release fuel pressure. See FUEL PRESSURE RELEASE . Drain coolant from radiator and cylinder block. Drain engine oil. Disconnect all necessary coolant hoses, electrical connectors, vacuum hoses, fuel lines and control cables. 2. Remove front exhaust tube. Remove intake manifold collector supports, and intake manifold. Remove exhaust manifold with catalytic converter. Remove air injection valve pipe. Remove intake air duct. Remove radiator fan and shroud. Remove injectors and fuel rail as an assembly. Remove distributor cap and spark plugs. 3. Set cylinder No. 1 at TDC of compression stroke, ensuring marks on crankshaft pulley and front cover align, and distributor rotor points to spark plug wire No. 1 on cap. Remove cylinder head cover. Remove distributor. NOTE: It is not necessary to install a stopper to prevent inner or outer timing chains from disengaging sprockets. 4. Prevent camshafts from turning, and remove camshaft sprocket bolts. Remove camshaft sprocket. See Fig. 13 . Mark and remove camshaft bearing caps in reverse order of installation. See Fig. 16 . Remove camshafts. 5. Loosen cylinder head bolts in 2 or 3 steps, in reverse order of tightening sequence. See Fig. 11 . Remove camshaft sprocket cover. Remove outer (upper) chain tensioner and guide. Remove outer timing chain. Remove idler sprocket bolt. Remove cylinder head. 6. Remove oil pan and oil strainer. See OIL PAN. Remove accessory drive belts. Remove A/C compressor idler pulley (if equipped). Remove crankshaft pulley. Remove front cover. Remove chain tensioner, tensioner arm and chain guides. Remove inner (lower) timing chain and idler sprocket. Remove oil pump drive spacer and crankshaft sprocket. Inspection 1. Inspect chain roller links. Replace chain if roller links are cracked or worn. Inspect cylinder head and cylinder block mating surfaces for warpage. If warpage exceeds specification, machine cylinder head. See CYLINDER HEAD under ENGINE SPECIFICATIONS. 2. If machining reduces cylinder head height to less than specification, replace cylinder head. After machining, rotate camshaft by hand. Replace cylinder head if camshaft does not rotate freely. Installation