Disassembly

1. Remove the bolts securing the oil pan.





2. Hammer in a 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, then remove the timing belt drive pulley.





6. Remove the balancer gear case.





7. Remove the front balancer driven pulley as shown.
8. Align the bolt hole and the balancer shaft hole, then insert a 6 x 100 mm bolt to hold the rear balancer shaft.





9. Remove the bolt and the balancer driven gear.





10. Remove the oil screen and the oil pump.
11. Remove the baffle plate.





12. Remove the bolts and the bearing cap bridge, then remove the bearing caps.

CAUTION: 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 and bearing caps.
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 bolts and the retainer, then remove the front balancer shaft and the rear balancer shaft.





19. If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer. Follow the reamer manufacturer's instructions.

CAUTION: If the ridge is not removed, it may damage the pistons as they are pushed out.





20. Use the wooden handle of a hammer to drive the pistons out.
21. Reinstall the connecting rod bearings and caps after removing each piston/connecting rod assembly.
22. 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.