Disassembly
Crankshaft, Piston and Balancer Shaft Removal1. Remove the bolts securing the oil pan.
2. Drive an oil pan seal cutter between the oil pan and cylinder block.
3. Cut the oil pan seal by striking the side of the cutter to slide the cutter along the oil pan. Remove the oil pan.
4. Remove the right side cover.
5. Remove the CKP/TDC sensors.
6. Remove the timing belt drive pulley.
7. Remove the balancer gear case.
8. Insert a screwdriver (A) in the front balancer shaft maintenance hole (B), and remove the front balancer driven pulley (C).
9. Remove the balancer driven gear.
-1 Remove the bolt (A) and washer (B) from the maintenance hole (C).
-2 Scribe a line on a 6 X 100 mm bolt, 74 mm (2.9 inch) from the end.
-3 Insert the bolt in the maintenance hole and into the hole in the rear balancer shaft (D) up to the line you scribed.
-4 Remove the bolt and balancer driven gear (E).
10. Remove the oil screen (A) and the oil pump (B).
11. Remove the baffle plate (C).
12. Remove the 6 mm bolts. To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.
13. Remove the 11 mm bolts. To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.
14. Remove the bearing cap bridge.
15. Turn the crankshaft so No. 2 and 3 crankpins are at the top.
16. Remove the rod caps/bearings and main caps/bearings. Keep all caps/bearings in order.
17. Lift the crankshaft (A) out of the engine, being careful not to damage the journals.
18. Remove the front balancer shaft and the rear balancer shaft.
-1 Remove the bolt and the retainer (A).
-2 Pull out the front balancer shaft (B).
-3 Pull out the rear balancer shaft (C).
19. Remove the upper bearing halves from the connecting rods, and set them aside with their respective caps.
20. Reinstall the main caps and bearings on the engine in the proper order.
21. If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer (A). Follow the reamer manufacturer's instructions. If the ridge is not removed, it may damage the pistons as they are pushed out.
22. Use the wooden handle of a hammer (A) to drive out the pistons (B).
23. Reinstall the connecting rod bearings and caps after removing each piston/connecting rod assembly.
24. To avoid mix-up on reassembly, mark each piston/connecting rod assembly with its cylinder number.
NOTE: The existing number on the connecting rod does not indicate its position in the engine, it indicates the rod bore size.