CYLINDER BLOCK DISASSEMBLY

PROCEDURE

  1. REMOVE OIL JET

    1. A324428

      Remove the oil jet from the cylinder block sub-assembly.

  2. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD SUB-ASSEMBLY

    Note:

    Do not turn the crankshaft.

    1. A324429N01

      Using SST, remove the 2 connecting rod bolts.

      09205-16011

      Note:

      Arrange the removed parts for each cylinder in the correct order.

    2. A324470

      Using the 2 removed connecting rod bolts, remove the connecting rod bearing cap and connecting rod bearing by wiggling the connecting rod bearing cap back and forth.

    3. Push the piston, connecting rod sub-assembly and connecting rod bearing through the top of the cylinder block sub-assembly.

      Tip:

      • Keep the piston, connecting rod sub-assembly and connecting rod bearing cap together.

      • Arrange the piston and connecting rod sub-assembly for each cylinder in the correct order.

  3. REMOVE CONNECTING ROD BEARING

    1. A324600

      Remove the connecting rod bearing from the connecting rod sub-assembly.

      Tip:

      Arrange the removed parts in the correct order.

    2. A324601

      Remove the connecting rod bearing from the connecting rod bearing cap.

      Tip:

      Arrange the removed parts in the correct order.

  4. REMOVE PISTON RING SET

    1. A324430

      Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring.

    2. Remove the expander spacer and 2 side rails by hand.

  5. REMOVE PISTON (w/ Pin)

    1. A109729

      Gradually heat each piston to approximately 80 to 90°C (176 to 194°F).

    2. Using SST, press the piston pin out of the piston, and remove the piston.

      A326887C01

      *1

      Connecting Rod Sub-assembly

      *2

      Piston Pin

      *3

      Piston

      -

      -

      09221-25026

      09221-00021

      09221-00030

      09221-00130

      09221-00141

      09221-00150

      Tip:

      • The piston and piston pin are a matched set.

      • Arrange the pistons, piston pins, connecting rod sub-assemblies and connecting rod bearings in the correct order.

  6. REMOVE CRANKSHAFT

    1. A324431N01

      Remove the 8 crankshaft bearing cap set bolts in the order shown in the illustration.

      Note:

      Loosen the crankshaft bearing cap set bolts in 2 or 3 steps in the order shown in the illustration.

    2. A324432

      Remove the 4 crankshaft bearing caps and 4 crankshaft bearings from the cylinder block sub-assembly.

      Note:

      Arrange the removed parts in the correct order.

      Tip:

      • If it is difficult to remove the crankshaft bearing cap, lightly tap it with a hammer.

      • Move the top of the crankshaft bearing cap back and forth in the axial direction.

    3. A324433

      Remove the crankshaft from the cylinder block sub-assembly.

  7. REMOVE CRANKSHAFT THRUST WASHER UPPER

    1. A324434

      Remove the 2 crankshaft thrust washer uppers from the No. 3 journal position of the cylinder block sub-assembly.

  8. REMOVE CRANKSHAFT BEARING

    1. A324435

      Remove the 4 crankshaft bearings from the cylinder block sub-assembly.

      Tip:

      Arrange the removed parts in the correct order.

    2. A324436

      Remove the 4 crankshaft bearings from the 4 crankshaft bearing caps.

      Tip:

      Arrange the removed parts in the correct order.

  9. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

    1. A324437

      Using a 5 mm hexagon socket wrench, remove the 3 bolts and 3 No. 1 oil nozzle sub-assemblies.