CYLINDER BLOCK DISASSEMBLY

PROCEDURE


  1. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    1. Check that the matchmarks on the connecting rod sub-assembly and connecting rod cap are aligned.

      Tech Tips

      The matchmarks on the connecting rod sub-assembly and connecting rod cap are guides for the correct reassembly.

    2. A01W1BI

      Remove the 2 connecting rod cap bolts.

      Text in Illustration
      B001OAO Engine Front
    3. A01W0AT

      Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

      Tech Tips

      Keep the lower bearing inserted to the connecting rod cap.

    4. A01W0KIE02
      Text in Illustration
      *1 Ridge Reamer

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

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

      Tech Tips


      • Keep the bearing, connecting rod and cap together.

      • Arrange the piston and connecting rod assemblies in the correct order.

  2. REMOVE CONNECTING ROD BEARING

    Tech Tips

    Arrange the removed parts in the correct order.

  3. REMOVE PISTON RING SET


    1. A01W1EZE02
      Text in Illustration
      *1 Piston Ring Expander

      Using a piston ring expander, remove the 2 compression rings.

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

      Tech Tips

      Arrange the removed parts in the correct order.

  4. REMOVE PISTON


    1. A01W05B

      Check the fitting condition between the piston and piston pin.


      1. Try to move the piston back and forth on the piston pin.

        If any movement is felt, replace the piston and pin as a set.

    2. A01W50K

      Disconnect the connecting rod from the piston.


      1. Using a screwdriver, pry off the piston pin hole snap rings from the piston.

      2. A01VZSP

        Gradually heat the piston to approximately 80°C (176°F).

      3. A01W00M

        Using a brass bar and a plastic hammer, lightly tap out the piston pin and remove the connecting rod sub-assembly.

        Tech Tips


        • The piston and piston pin are a matched set.

        • Arrange the pistons, piston pins, piston pin hole snap rings, connecting rods and connecting rod bearings in the correct order.

    3. A01W5NA

      Using a gasket scraper, remove the carbon from the piston top.

      Note

      Be careful not to scratch a piston.

    4. Using a groove cleaning tool, clean the piston ring grooves.

    5. A01W0UH

      Using solvent and a brush, thoroughly clean the piston.

      Note

      Do not use a wire brush.

  5. REMOVE CRANKSHAFT


    1. A01W3PKE04

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

    2. A01W4VTE07

      Uniformly loosen the 16 crankshaft bearing cap bolts, in several steps and in the sequence shown in the illustration.

    3. A01W1U3E01
      Text in Illustration
      *1 Protective Tape
      *2 Cylinder Block Sub-Assembly
      *3 Bearing Cap
      *a Joint Surface

      Using a screwdriver, pry out the crankshaft bearing caps. Remove the 4 crankshaft bearing caps and lower crankshaft bearings.

      Note


      • Push up on the cap slowly and evenly, alternating from the right and left side so that the bearing cap can be removed.

      • Be careful not to damage the joint surface of the cylinder block sub-assembly and the crankshaft bearing cap.

    4. Remove the crankshaft.

  6. REMOVE CRANKSHAFT BEARING


    1. Remove the upper crankshaft bearings and lower crankshaft bearings.

      Tech Tips

      Arrange the removed parts in the correct order.

  7. REMOVE CRANKSHAFT THRUST WASHER SET


    1. A01W1VT

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

  8. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A01W4XW

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

    2. Check the 3 No. 1 oil nozzle sub-assemblies for damage or clogging.

      If necessary, replace the No. 1 oil nozzle sub-assembly.

  9. CLEAN CYLINDER BLOCK SUB-ASSEMBLY