Disassembly
REMOVE FLYWHEEL OR DRIVE PLATEFlywheel:
Manual Transmission:
Remove the eight flywheel bolts, then separate the flywheel from the crankshaft flange. After installation, tighten the bolts in the sequence shown. 12 x 1.0 mm Bolt Torque: 105 Nm (10.5 kg-m, 76 lb ft)
Drive Plate:
Automatic Transmission:
Remove the eight drive plate bolts, then separate the drive plate from the crankshaft flange. After installation, tighten the bolts in the sequence shown. 12 x 1.0 mm Bolt Torque: 75 Nm (7.5 kg-m, 54 lb ft)
BLOCK DISASSEMBLY PROCEDURE
NOTE: Inspect crankshaft, balance shaft, and connecting rod end play before disassembling block.
Side Cover Removal:
1. Remove the right side cover.
Balancer Drive Removal:
2. Remove the balancer drive gear case.
Balancer Driven Pulley Removal:
3. Remove the front balancer driven pulley as shown.
4. Align the bolt hole and the balancer shaft hole, then insert a 6 x 100 mm bolt to hold the rear balancer shaft.
5. Remove the bolt and the balancer drive gear.
Oil Pump Removal:
6. Remove the oil screen and the oil pump.
7. Remove the baffle plate.
Main Bearing Loosening Sequence:
8. 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.
Crankshaft Removal:
9. Turn the crankshaft so No. 2 and 3 crankpins are at the bottom.
10. Remove the rod caps/bearings and main caps/bearings. Keep all caps/bearings in order.
11. Lift the crankshaft out of the engine, being careful not to damage journals.
Balancer Shaft Removal:
12. Remove the bolts and the retainer, then remove the front balancer shaft and the rear balancer shaft.
13. Remove the upper bearing halves from the connecting rods and set them aside with their respective caps.
14. Reinstall the main caps and bearings on the engine in proper order.
Cylinder Ridge Removal:
15. 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.
Piston Removal:
16. Use the wooden handle of a hammer to drive the pistons out.
17. Reinstall the rod bearings and caps after removing each piston/connecting rod assembly.
18. Mark each piston/connecting rod assembly with its cylinder number to avoid mix-up on reassembly.
NOTE: The existing number on the connecting rod does not indicate its position in the engine, it indicates the rod bore size.