Remove
Engine – see operation "Engine without Transmission, Remove and Install (4JA1TC)".
Place engine on Engine Overhaul Stand KM-412 (remove lower fuel injection pump bracket).
Engine oil – drain.
Cylinder head – see operation "Cylinder Head, Remove and Install (4JA1TC)".
Remove
Clutch pressure plate and friction disc from flywheel – bolts.
Flywheel from crankshaft - bolts and washer plate loosen uniformly in sequence shown.
Remove
Rear plate from cylinder block – three bolts.
Oil pan – see operation "Oil Pan Gasket, Replace".
Remove
Oil pump from cylinder block, pipe union and bolts.
Remove
Water hoses (1) from inlet and outlet coolant pipes of oil cooler.
Oil filter assembly – bolts (2). Illustration shows 4JA1T engine.
Remove
Fuel injection pump from timing gear case, upper support bracket from engine block.
Timing gear case — see operation “Gasket — Timing Gear Case, Replace”.
Crankshaft gear from crankshaft using commercially available puller.
Cylinder block from engine stand KM-412.
Install
New short cylinder block to engine stand KM-412.
Timing gear case with new gasket to cylinder block — 19 Nm.
Crankshaft gear to crankshaft using KM-J-26587.
Note. The timing marks have to face the front.
Idler gear to hub, align timing mark on idler gear with timing mark on crankshaft gear.
Idler gear with thrust collar to hub — 2 bolts 19 Nm.
Camshaft gear to camshaft, align timing mark on camshaft gear with timing mark on idler gear. Mind the position of the woodruf key in the camshaft.
Camshaft gear to camshaft with washer — bolt 108 Nm. Hold crankshaft on starter ring gear.
Install
Scissors gear to cylinder block, align timing mark on scissors gear with timing mark on idler gear — bolt 108 Nm.
Note. The timing marks have to face the front.
Fuel injection pump to timing gear case, align timing mark on fuel injection pump gear with timing mark on scissors gear.
Fuel injection pump upper support bracket to cylinder block — 25 Nm.
Unlock scissors gear.
Inspect
Inspect crankshaft front oil seal and if neccesary replace — see operation “Crankshaft Oil Seal, Front, Replace (4JA1TC)”.
Clean
Sealing surfaces for timing gear cover oil seal.
Install
Oil seal to timing gear cover.
Timing gear cover to timing gear case and fuel injection pump — bolts 19 Nm.
Crankshaft damper pulley to crankshaft hub — bolt 206 Nm. Hold crankshaft by locking starter ring gear.
Water pump pulley to water pump hub.
Install
O-ring for pipe of oil pump - coat in clean engine oil.
Oil pump and pipe with O-ring to block – bolts 19 Nm, sleeve nut 25 Nm.
Oil pan – see operation "Oil Pan Gasket, Replace".
Rear plate to cylinder block – three bolts 83 Nm.
Install
Oil filter assembly – bolts (2) — 14 Nm. Illustration shows 4JA1T engine.
Water hoses (1) to inlet and outlet coolant pipes of oil cooler.
Install
Flywheel to crankshaft - bolts and washer plate in sequence shown – bolts 118 Nm.
Clutch pressure plate and friction disc to flywheel – bolts 18 Nm.
Cylinder head – see operation "Cylinder Head, Remove and Install (4JA1TC)".
Engine – see operation "Engine without Transmission, Remove and Install (4JA1TC)". Prior install lower fuel injection pump bracket to cylinder block — bolts 40 Nm.
Replenish engine oil and coolant.