Remove
Engine - see operation "Engine without Transmission Remove and Install".
Place engine on Engine Overhaul Stand KM-412.
Drain engine oil.
Remove
Timing belt and cylinder head – see operations "Timing Belt Remove and Install" and "Cylinder Head Remove and Install".
Centre bolt of camshaft pulley – align hole in pulley with threaded hole in cylinder block then fit bolt to restrain pulley.
Camshaft pulley from camshaft – use KM-6440.
Remove
Crankshaft pulley boss from crankshaft - use KM-J-8614-01.
Crankshaft timing pulley from crankshaft.
Remove
Timing pulley housing from cylinder block (see illustration).
Remove
Flywheel plate and bolts from crankshaft – loosen bolts uniformly in sequence shown.
Remove
Rear plate from cylinder block – three bolts.
Remove
Oil return pipe (arrowed) of turbocharger to oil pan - bolts and dipstick tube from oil pan.
Remove
Oil pan bolts and nuts release pan from cylinder block - use KM-J-37228.
Remove
Oil pump from cylinder block pipe union and bolts.
Turn crankshaft until con-rod bearing cap to be replaced is at bottom dead centre.
Remove
Con-rod bearing cap and bearing shells - bolts.
Remove
Main bearing caps from cylinder block – loosen bolts uniformly in sequence shown.
Crankshaft and main bearing shells from cylinder block.
Clean
All parts.
Inspect
Crankshaft and shells - see operation "Crankshaft Check".
Caution
Refer to bearing selection paying close attention to cylinder block bearing housing size mark and crankshaft journal diameter size mark - see 'Technical Data' for bearing details.
Install
Main bearing shells and main bearing caps to cylinder block - ensure shells are correctly positioned grooved bearing shells (arrowed) in cylinder body plain bearing shells in bearing caps; apply clean engine oil to bearing surfaces.
Crankshaft into cylinder block.
Install
Thrust washer (arrowed) to number 3 journal with oil grooves facing crankshaft.
Install
Oil pan seal (arrowed) to number 5 bearing taking care not to scratch seal outer surface.
Apply liquid gasket to number 5 bearing cap and cylinder block mating surfaces at points (arrowed).
Caution
Ensure mating surfaces of bearing cap are completely free from oil.
Do not allow liquid gasket to obstruct threaded holes and bearings.
Install
Bearing caps to cylinder block with arrow mark facing toward front of engines - oil bolts but do not fully tighten at this stage.
Crankshaft rear oil seal - see operation "Crankshaft Rear Oil Seal Remove and Install".
Install
Main bearing cap bolts - fully tighten 167 Nm uniformly in sequence shown.
Inspect
Crankshaft for smooth rotation.
Install
Con-rod bearing caps – see operation "Piston with Con-rod Remove and Install".
Caution
Coat teeth of oil pump pinion with solution of 80% engine oil and 20% molybdenum before assembly.
Install
O-ring for pipe of oil pump – coat in clean engine oil.
Oil pump and oil pipe with O-ring to cylinder block bolts 19 Nm sleeve nut 25 Nm.
Oil pan – see operation "Oil Pan Gasket Replace".
Install
Rear plate to cylinder block - bolts 82 Nm.
Flywheel - see operation "Flywheel Remove and Install".
Install
Timing pulley housing with gasket to cylinder block - take care not to damage crankshaft front oil seal; bolts 19 Nm.
Install
Crankshaft timing pulley – use KM-J-26587 with flange on timing pulley toward engine; bolt 64 Nm.
Camshaft pulley - align keyway; hand-tighten centre bolt; align hole in pulley with threaded hole in cylinder block then fit bolt through hole to restrain pulley; tighten centre bolt 206 Nm; remove restraining bolt.
Caution
Check piston protrusion prior to selecting cylinder head gasket.
Install
Cylinder head - see operation "Cylinder Head Remove and Install".
Timing belt - see operation "Timing Belt Remove and Install".
Install
Engine - see operation "Engine without Transmission Remove and Install".
Replenish engine oil and coolant.