FO16878 Force THROTTLE SHUTTER

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 9U-6198 Crankshaft Turning Tool 1
A(2) 9U-7336 Housing 1
5P-7305 Engine Turning Tool 1
B 230-6283 Timing Pin (Crankshaft) 1
C 370-8376 Capping Kit 1
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.Start By:
If necessary, remove the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install" for the correct procedure.
If necessary, remove the fuel priming pump. Refer to Disassembly and Assembly, "Fuel Priming Pump - Remove" for the correct procedure.
If necessary, remove the crankcase breather (Filtered Breather). Refer to Disassembly and Assembly, "Crankcase Breather (Filtered Breather) - Remove" for the correct procedure. Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Turn the fuel supply to the OFF position.
Turn the battery disconnect switch to the OFF position.
Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure.
Use Tooling (A) in order to rotate the crankshaft so that number one piston is in the Top Dead Center Position on the compression stroke.
Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure.
Illustration 1 g03669804
Install Tooling (B) through Hole (X) in order to lock the crankshaft.
Remove nut (3) and spring washer (4) (not shown).
Remove gear (1) from fuel injection pump shaft (2).
Illustration 2 g03672188
Illustration 3 g03672189
Place a suitable container below fuel injection pump (13) in order to catch any fuel that might be spilled.
Clean fuel injection pump (13) and the area around the fuel injection pump. Ensure that the area is free from contamination before beginning disassembly.
Remove fuel injection lines (5) from the fuel injection pump and the fuel manifold. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove" for the correct procedure. Note: Discard the fuel injection lines.
Remove banjo bolt (6) from tube assembly (8). Remove sealing washers (7) (not shown). Use Tooling (C) in order to plug the tube assembly. Cap the ports in the fuel injection pump.
Disconnect harness assembly (9) from flow control valve (10). Note: The harness assembly should be repositioned in order to avoid obstructing the fuel injection pump removal.
Disconnect the tube assembly (not shown) from connection (14). Use Tooling (C) in order to plug the tube assembly. Cap the connection in the fuel injection pump.
Disconnect the tube assembly (12) from connection (11). Use Tooling (C) in order to plug the tube assembly. Cap the connection in the fuel injection pump.
Remove banjo bolt (16) from tube assembly (15). Remove sealing washers (17) (not shown). Use Tooling (C) in order to plug the tube assembly. Cap the ports in the fuel injection pump.
Remove banjo bolt (22) from tube assembly (21). Remove sealing washers (23) (not shown). Use Tooling (C) in order to plug the tube assembly. Cap the ports in the fuel injection pump.
Remove banjo bolt (19) from tube assembly (21). Remove sealing washers (18) (not shown). Use Tooling (C) in order to plug the tube assembly. Cap the ports in the fuel injection pump.
Remove tube assembly (21) from clip (20).
Illustration 4 g03673275
Remove the nut and bolt (29) from bracket (30).
Remove bolts (27) and remove bracket (28) from the cylinder block.
Remove bolts (26) from fuel injection pump (13). Support the fuel injection pump as the bolts are removed.
Remove the fuel injection pump from front housing (25).
Remove O-ring seal (24) (not shown).
Illustration 5 g03673295
If necessary, follow Step 25.a through Step 25.b in order to remove the bracket from the fuel injection pump.
Position fuel injection pump (13) in a suitable stand.
Remove bolts (31) and remove bra