Remove
Engine – see operation "Engine without Transmission, Remove and Install".
Place engine on Engine Overhaul Stand KM-412.
Engine oil drain.
Cylinder head – see operation "Cylinder Head Remove and Install".
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).
Remove
Crankshaft damper pulley from hub – four bolts.
Timing belt covers.
Alternator with bracket and vacuum pump.
Timing belt tension pulley assembly timing belt from pulleys.
Crankshaft pulley boss and timing pulley from crankshaft – use Holder KM-J-8614-01 and Remover KM-8060.
Remove
Pulleys from camshaft and fuel injection pump - use KM-6440.
Remove
Injector pipes and fuel hoses from fuel injection pump.
Harness connectors and vacuum hose from fuel injection pump.
Fuel injection pump from timing gear case support bracket (arrowed) from engine block – nuts and bolts.
Remove
Water pump from cylinder block - bolts.
Power steering pump and adjuster bracket from cylinder block - bolts.
Remove
Timing pulley case from cylinder block - bolts.
Remove
Cylinder block from engine stand KM-412.
Install
New short cylinder block to engine stand KM-412.
Install
Timing pulley case to cylinder block - bolts.
Install
Fuel injection pump – see operation "Fuel Injection Pump Remove and Install".
Install
Tensioner pulley assembly idler pulley - bolt 76 Nm.
Camshaft pulley - bolt 64 Nm.
Water pump - bolts 20 Nm.
Crankshaft timing pulley.
Install
Timing belt – see operation "Timing Belt Remove and Install".
Install
Power steering pump and bracket – see operation "Power Steering Pump Remove and Install" in group M.
Install
Timing belt upper and lower covers - apply liquid gasket (arrowed) to lower cover.
Crankshaft pulley hub - bolt 4JA1T 186 Nm 4JG2T 274 Nm.
Crankshaft damper pulley to 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".
Install
Filter housing with oil cooler gasket and filter hoses (1) bolts (2) – 20 Nm.
Alternator and vacuum pump with bracket.
Install
Cylinder head – see operation "Cylinder Head Remove and Install".
Flywheel - see operation "Flywheel Remove and Install".
Engine.
Replenish engine oil and coolant.