Engine, Repair Using Short Block
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Engine - see corresponding operation.
Place engine on Engine Overhaul Stand KM - 412.
Drain engine oil.
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Exhaust and intake manifold - see corresponding operations.
| Cylinder head - see corresponding operation. | |||
|---|---|---|---|
| .P. U5534.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Starter.
Clutch pressure plate and friction disc - see operation in group K.
Flywheel.
| Cylinder body rear plate. | |||
|---|---|---|---|
| .P. U2473.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
| Oil pan, oil pump, oil filter assembly - see corresponding operations. | |||
| .P. U2598.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
| Cooling fan, timing gear covers, alternator and bracket, timing belt, crankshaft timing pulley, crankshaft oil seal - see corresponding operations. | |||
| .P. U3404.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
| Camshaft and fuel injector pump pulleys - use KM - 651, fuel injection pump, timing belt idler pulleys. | |||
| .P. U2470.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
| Water pump, power steering pump and bracket, air conditioning compressor and bracket, timing pulley housing. | |||
| .P. U2476.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Cylinder block from Engine Overhaul Stand KM - 412.
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
New short block on Engine Overhaul Stand KM - 412.
Timing pulley housing to cylinder block.
Crankshaft oil seal - see corresponding operation.
| .D. ICON09.tif | 0,75 | 0,75 | tiff;; Tighten (Torque) |
|---|---|---|---|
| Timing pulley housing bolts - 19 Nm / 14 lbf ft. | |||
| .P. U2476.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Air conditioning compressor and bracket, power steering pump and bracket. Fuel injection pump - see corresponding operation, fuel injection pump pulley, camshaft pulley, idler pulley, crankshaft timing pulley, water pump, timing belt - see corresponding operations.
| .D. ICON09.tif | 0,75 | 0,75 | tiff;; Tighten (Torque) |
Fuel injection pump pulley nut - 64 Nm / 47 lbf ft.
Camshaft pulley centre boss bolt - 64 Nm / 47 lbf ft.
Idler pulley bolt - 76 Nm / 56 lbf ft.
| Water pump bolts - 20 Nm / 15 lbf ft. | |||
|---|---|---|---|
| .P. U3406.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Timing belt upper and lower covers - apply liquid gasket (arrowed) to lower cover.
Crankshaft pulley boss, crankshaft damper pulley to hub.
| .D. ICON09.tif | 0,75 | 0,75 | tiff;; Tighten (Torque) |
|---|---|---|---|
| Crankshaft damper pulley boss bolt - 206 Nm / 152 lbf ft. | |||
| .P. U3420.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Oil pan and oil pump - see corresponding operation.
Filter housing with oil cooler and new oil filter element and gasket.
Alternator with bracket and vacuum pump.
| .D. ICON09.tif | 0,75 | 0,75 | tiff;; Tighten (Torque) |
|---|---|---|---|
| Filter housing bolts and nuts - 19 Nm / 14 lbf ft. | |||
| .P. U2598.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
| Cylinder head to cylinder block - see corresponding operation. | |||
| .P. U6180.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Engine rear cover.
Flywheel, starter.
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Engine assembly.
| Replenish engine oil and coolant. | |||
|---|---|---|---|
| .P. U5534.tif | 9 | 7,5 | tiff;; |