Page 1681 of 3573

FUEL SYSTEM 6C Ð 15
REMOVAL
Preparation:
·Disconnect battery ground cable.
·Drain coolant.
1. Air Cleaner Cover & Air Duct
2. Intercooler Assembly (4JG2-T ONLY)
· Refer to Intercooler Assembly removal.
3. Radiator Assembly
·Disconnect upper and lower hoses on the engine
side.
4. Cooling Fan Assembly
·Remove cooling fan asm and remove fan pulley
and spacer.
5. P/S Pump Drive Belt
·Loosen P/S pump lock bolt and adjust bolt remove
two drive belts.
6. AC Generator Drive Belt
·Loosen AC generator mounting bolt (under side)
and adjust, bolt and remove drive belt.
7. Timing Gear
·Refer to Timing Gear Removal
·Remove the loosened nut and fixing bolt and
remove the timing gear.
8.Fuel Filter Assembly
9. Injection Pump Harness
·Remove tachometer sensor, throttle sensor, and
fuel cut solenoid, harness.
10. Fuel Hose & CSD Hose
·Disconnect inlet hose and outlet hose and keep
hose end up to prevent fuel from coming out.
·Disconnect CSD hose.
11. Injection Pump Control Cable
12. Injection Pipe
·Release pipe clip.
·Remove the flare nut on the pump side.
·Remove the flare nut on the injection nozzle side,
and remove the injection pipe.
CAUTION
·Be sure to plug the injection nozzle holder and
delivery holder to prevent the entry of foreign
matter.
13. Injection Pump Assembly
·Remove pump mounting nut
·Loosen injection pump rear bracket adjuster lock
bolt.
·Remove the mounting bolt on the engine side, and
pull out the pump behind the engine.
Page 1682 of 3573

6C Ð 16 FUEL SYSTEM
20 (2.0/15)N·m (Kg·m/lb·ft)
·Tighten the injection pump bracket bolts 8 to the
specified torque..
40 (4.1/30)N·m (Kg·m/lb·ft)
12. Injection Pipe
·Connect the pump side and nozzle side of the pipe,
and tighten securely.
·Install clip where it was.
11. Injection Pump Control Cable
·See adjustment of accelerator control cable.
10. Fuel Hose & CSD Hose
9. Injection Pump Harness
·Mount engine harness and connect it to switches.
8. Fuel Filter Assembly
7. Timing Gear
·Refer to Timing Gear in Section 6A2.
6. AC Generator Drive Belt
·Mount AC Generator drive belt and adjust belt
tension.
·See drive belt adjustment in section 6B.
5. P/S Pump Drive Belt
·Mount P/S pump drive belt and adjust belt tension.
·See drive belt adjustment in section 6B.
4. Cooling Fan Assembly
·Mount fan pulley, distance piece, and cooling fan
asm (in this order) on the water pump, and tighten
to the specified torque.
3. Radiator Assembly
2. Intercooler Assembly (4JG2-T ONLY)
·See installation of intercooler.
·Pour coolant.
·Connect battery ground cable.
1. Air Cleaner Cover & Air Duct
INSTALLATION
13. Injection Pump Assembly
·Tighten the injection pump bracket bolts 7 to the
specified torque..
8 (0.8/69)N·m (Kg·m/lb·in)
Page 1683 of 3573

FUEL SYSTEM 6C Ð 17
·If it reads abnormal, loosen injection pump fixing nut
and pump bracket adjust bolt, make adjustment by
changing the pump mounting angle, and tighten
the nut and bolt to the specified torque where the
dial indicates the specified valve.
Pump fixing nut
Adjust bolt
·Remove the measuring device and tighten the
distributor head plug to the specified torque.
CAUTION
·When installing the distributor head plug, be sure to
use new copper washer.
·Connect injection pipe.
·Fit pipe clip where specified.
INJECTION TIMING ADJUSTMENT
·Set No.1 cylinder to top dead center.
·Remove injection pump distributor head plug.
·Cancel wax CSD with the handle of a driver.
·Fit a dial gauge and set lift to 2 mm(0.0787 in).
Measuring device: 5-8840-0145-0
·Set crankshaft damper pully top dead center mark
about 45¡ before top dead center from the pointer.
·Set dial gauge in the Ò0Ó position.
·Turn the crankshaft a little rightwise and leftwise
and see if the pointer is stable in the Ò0Ó position.
·Turn the crankshaft in the normal direction and
read the measuring diviceÕs indication at TDC
(4JG2-T) and ATDC 1¡ (4JG2-NA)
0.5 (0.0197)mm(in)Standard
19 (1.9/13)
N·m (Kg·m/lb·ft)
40 (4.1/30)
N·m (Kg·m/lb·ft)
17 (1.7/12)N·m (Kg·m/lb·ft)
Page 1684 of 3573
6C Ð 18 FUEL SYSTEM
FUEL TANK
4. Fuel tank wiring connector
5. Evapo fuel hose
6. Fuel hose and fuel return hose
7. Fuel tank
Installation Steps
To install, follow the removal steps in the
reverse order.
Removal Steps
1. Inner liner
2. Fuel filler hose and breather hose
3. Under cover
REMOVAL
Preparation:
·Disconnect battery ground cable.
·Loosen fuel filler cap.
·Drain fuel.
·Tighten drain plug to the specified torque after drain-
ing fuel.
20 (2.0/14)
N·m (Kg·m/lb·ft)
1. Inner Liner
·Remove inner liner of wheel arch on rear right side.
2. Fuel Filler Hose and Air Breather Hose
3. Under Cover
·Remove undercover fixing bolts on both sides.
4. Fuel Tank Wiring Connector
·Disconnect two connectors on front right side of tank.
5. Evapo Fuel Hose
6. Fuel Hose and Fuel Return Hose
7. Fuel Tank
·Remove fuel tank fixing bolts on both sides.
Page 1685 of 3573
FUEL SYSTEM 6C Ð 19
6. Fuel Hose and Fuel Return Hose
5. Evapo Fuel Hose
4. Fuel Tank Wiring Connector
3. Under Cover
2. Fuel Filler Hose and Air Breather Hose
1. Inner Liner
·Mount inner liner on the wheel arch.
·Fill the tank with fuel and tighten fuel filler cap.
·Connect battery ground cable.
36 (3.7/27)N·m (Kg·m/lb·ft)
FUEL GAUGE UNIT
Installation Steps
To install, follow the removal steps in the
reverse order.
Removal Steps
1. Wiring connector
2. Fuel gauge unit
INSTALLATION
7. Fuel Tank
·Place a flange on right side of tank on the bracket.
·Install a flange on left side on the bracket from the
bottom, and tighten bolts to the specified torque.
Page 1686 of 3573
6C Ð 20 FUEL SYSTEM
REMOVAL
Preparation:
·Disconnect battery ground cable.
·Loosen fuel filler cap.
·Drain fuel.
·Tighten drain plug to the specified torque after drain-
ing fuel.
1. Wiring Connector
¥ Drain fuel
2. Fuel Gauge Unit
¥ Remove the fixing screws, then the fuel gauge unit.
INSTALLATION
2. Fuel Gauge Unit
1. Wiring Connector
¥ Connect the wiring connector to the fuel gage unit.
¥ Fill the tank with fuel and tighten fuel filler cap.
¥ Connect battery ground cable.20 (2.0/14)
N·m (Kg·m/lb·ft)
The fuel filler cap contains a vacuum valve. If a negative
pressure develops in the fuel tank, the external valve of
fuel filler cap opens to allow the fresh air to flow into the
fuel tank through the vacuum valve.
INSPECTION
Check the seal ring in the filler cap for presence of any
abnormality and for seal condition.
Replace the filler cap, if abnormal.
FUEL FILLER CAP
Page 1687 of 3573
FUEL SYSTEM 6C Ð 21
ACCELERATOR CONTROL
ACCELERATOR CONTROL CABLE
REMOVAL
1. Adjusting Nut
·Loosen the adjust nut on the cable bracket
mounted on the injection pump.
2. Accelerator Control Cable (on injection pump
side)
3. Accelerator Control Cable (on accelerator pedal
side)
4. Grommet
5. Accelerator Control Cable
INSPECTION
Check the following items, and replace the control cable
if any abnormality is found.
·The control cable should move smoothly.
·The control cable should not be bent or kinked.
·The control cable should be free of damage and
corrosion.
Removal Steps
1. Adjusting nut
2. Accelerator control cable
(Injection pump side)3. Accelerator control cable
(Accelerator pedal side)
4. Grommet
5. Accelerator control cable
Installation Steps
To install, follow the removal steps in the
reverse order.
Page 1688 of 3573
6C Ð 22 FUEL SYSTEM
INSTALLATION
5. Adjusting Nut
4. Accelerator Control Cable (on injection pump
side)
3. Accelerator Control Cable (on accelerator pedal
side)
2. Grommet
1. Accelerator Control Cable
Adjustment of Accelerator Control Cable
1. Loosen the lock nut.
2. Lock the throttle valve fully closed, and pull the outer
cable. Then, adjust the nut B so that the clearance
between nut B and bracket is as shown in figure.
3. Push the nut B against the bracket and tighten nut A to
lock the cable.