Disassembly and assembly

KENR6226-01 11
Disassembly and Assembly Section
NOTICE
Do not let the tops of fuel injectors turn when the fuel
line nuts are lo
osened or tightened.
The fuel injectors will be damaged if the top of the
injector turns
in the body.
The engine will be damaged if a defective fuel injector
is used becaus
e the shape of fuel (spray pattern) that
comes out of the nozzle will not be correct.
Note: The installation procedure is similar for the
two cylinder,
the three cylinder and the four cylinder
engines.
g01326555
Illustration 11
Typical e
xample
1. Remove the caps from fuel injectors (7). Install
new washe
rs (6) and fuel return line (3) to fuel
injectors (7).
Note: Th
e washers (6) have two small holes.
2. Install nuts (5) to fuel injectors (7).
3. The 403D-15, 403D-15T, 403D-17, 404D-22,
404D-22TA and 404D-22TA engines have a rigid
fuel ret
urn line.
For engines with a rigid fuel return line, install new
washers
(8) t o fuel return line (3) and install banjo
bolt (4) to the fuel injection pump. Tighten banjo
bolt (4) to a torque of 7 N·m (62 lb in).
The 402D-05, 403D-07, 403D-11 and 404D-15
engines have a fl
exible fuel return hose.
For engines with a flexible fuel return hose,
connect the fu
el return hose to the fuel injection
pump.
4. Tighten nuts (
5)toatorqueof27N·m(20lbft).
g01326550
Illustration 12
Typical example
5. Remove the caps from the outlet connections of
the fuel injection pump. Install the fuel injection
lines to the engine as a unit.
6. Connect fuel injection lines (2) to fuel injectors (7).
Tighten the union nuts (1) finger tight.
7. Use Tooling (A) to tighten union nuts (1) at the fuel
injection pump.
For 402D-05 and 403D-07 engines, tighten union
nuts (1) to a torque of 20 N·m (15 lb ft).
For 403D-11, 403D-15, 403D-15T, 403D-17,
404D-15, 404D-22, 404D-22T and 404D-22TA
engines, tighten the union nuts (1) to a torque of
23 N·m (17 lb ft).
Note: For the three cylinder and the four cylinder
engines, tighten the center union nuts first.
8. Use Tooling (A) to tighten union nuts (1) at the fuel
injections.
For 402D-05 and 403D-07 engines, tighten union
nuts (1) to a torque of 20 N·m (15 lb ft).
This document has been printed from SPI². Not for Resale