CYLINDER BLOCK DISASSEMBLY

PROCEDURE

1. REMOVE NO.1 BALANCESHAFT

   1. 

      *1

      Cap

      Using a screwdriver with its tip wrapped with protective tape, remove the cylinder block tight plugs.

   2. 

      Remove the 4 bolts and cylinder block side cover from the cylinder block sub-assembly.

   3. 

      Turn the crankshaft and No. 1 balanceshaft so that they are positioned as shown in the illustration.

   4. Using SST, secure the crankshaft and No. 1 balanceshaft.

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      Note:

      Check that SST is correctly positioned on the No. 1 balanceshaft as shown in the illustration.

      

      *1

      No. 1 Balanceshaft

      -

      -

   5. 

      Using an E12 "TORX" socket wrench, remove the bolt.

   6. 

      Remove the balance weight and No. 1 balanceshaft driven gear.

   7. 

      Remove the No. 1 balanceshaft as shown in the illustration.

2. REMOVE NO. 1 AND NO. 2 BALANCESHAFT BEARING

   1. 

      *1	No. 1 Balanceshaft Bearing

      Using SST, remove the No. 2 balanceshaft bearing.

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   2. 

      Remove the stop-ring.

   3. 

      *1	No. 2 Balanceshaft Bearing

      Using SST, remove the No. 1 balanceshaft bearing.

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3. REMOVE PISTON WITH CONNECTING ROD

   1. 

      *a	Ridge Reamer

      Using a ridge reamer, remove all the carbon from the top of the cylinder.

   2. Remove the 6 connecting rod bolts, 3 connecting rod caps and 3 connecting rod bearings.

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

      Tip:

      • Keep the connecting rod bearings, connecting rod and connecting rod cap together.

      • Be sure to arrange the removed piston and connecting rod in such a way that they can be reinstalled exactly as before.

4. REMOVE CONNECTING ROD BEARING

   1. Remove the connecting rod bearings from the connecting rod sub-assemblies and connecting rod caps.

      Tip:

      Arrange the removed parts in the correct order.

5. INSPECT CRANKSHAFT THRUST CLEARANCE

   1. 

      Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

      Standard Thrust Clearance

      0.07 to 0.42 mm (0.00276 to 0.0165 in.)

      If the thrust clearance is more than the maximum, replace the crankshaft thrust washers as a set. If necessary, replace the crankshaft.

      Standard Thrust Washer Thickness

      2.35 mm (0.0925 in.)

6. REMOVE CRANKSHAFT

   1. 

      Uniformly loosen and remove the 8 crankshaft bearing cap bolts in several steps in the order shown in the illustration.

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

      Tip:

      • Keep the No. 2 crankshaft bearings and crankshaft bearing caps together.

      • Arrange the removed parts in the correct order.

   3. Remove the crankshaft from the cylinder block sub-assembly.

      Tip:

      Keep the crankshaft bearings and crankshaft thrust washers together with the cylinder block sub-assembly.

   4. Check each crankshaft journal and crankshaft bearing for pitting and scratches.

      If the journal or crankshaft bearing is damaged, replace the crankshaft bearings. If necessary, replace the crankshaft.

7. REMOVE CRANKSHAFT THRUST WASHER

   1. 

      Remove the 2 crankshaft thrust washers from the cylinder block sub-assembly.

8. REMOVE CRANKSHAFT BEARING

   1. Remove the 4 crankshaft bearings and 4 No. 2crankshaft bearings from the cylinder block sub-assembly and crankshaft bearing caps.

      Tip:

      Arrange the removed parts in the correct order.

9. REMOVE PISTON RING SET

   1. 

      *a	Piston Ring Expander

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

   2. Remove the oil ring and oil ring expander by hand.

      Tip:

      Arrange the removed parts in the correct order.

10. REMOVE PISTON

    1. Gradually heat each piston to approximately 100 °C (212 °F).

    2. 

       Using SST, press out the piston pin from thepiston. Remove the piston.

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       Tip:

       • The piston and piston pin are amatched set.

       • Be sure to arrange the removed pistons, piston pins, piston rings, connecting rod sub-assemblies and connecting rod bearings in such a way that they can be reinstalled exactly as before.