CYLINDER BLOCK(w/ DPF) DISASSEMBLY

PROCEDURE


  1. REMOVE TUBE CONNECTOR


    1. A01VK7DE05
      Text in Illustration
      *a 14 mm Deep Socket Wrench

      Using a 14 mm deep socket wrench, remove the tube connector from the cylinder block sub-assembly.

  2. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    1. A01VEMXE01

      Using SST, remove the connecting rod bolts and connecting rod cap.

      SST
      09205-16011
    2. A01VKRE

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

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

      Tech Tips


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

      • Keep the pistons and connecting rods in the correct order so that they can be returned to their original locations when reassembling.

  3. REMOVE CONNECTING ROD BEARING


    1. A01VJS1

      Remove the connecting rod bearing (lower) from the connecting rod cap.

    2. A01VG46

      Remove the connecting rod bearing (upper) from the connecting rod.

  4. REMOVE CRANKSHAFT


    1. A01VLACE02

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

    2. Remove the crankshaft bearing caps and crankshaft.

  5. REMOVE UPPER CRANKSHAFT THRUST WASHER


    1. A01VE6X

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

  6. REMOVE CRANKSHAFT BEARING


    1. A01VIV5

      Remove the crankshaft bearing (upper) from the cylinder block sub-assembly.

    2. A01VKLW

      Remove the crankshaft bearing (lower) from the crankshaft bearing cap.

  7. REMOVE PISTON RING SET

    Tech Tips

    Keep the piston rings in the correct combination and order so that they can be returned to their original locations when reassembled.


    1. A01VI53

      Using a piston ring expander, remove the No. 1 compression ring, No. 2 compression ring, oil ring (side rail) and oil ring (expander).

  8. REMOVE PISTON


    1. A01VJ1Z

      Using a screwdriver, pry out the snap ring and remove the piston pin.

      Note

      Do not change the combinations of the pistons and piston pins.

  9. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A01VHAO

      Using a 5 mm socket hexagon wrench, remove the 4 bolts and 4 No. 1 oil nozzle sub-assemblies from the cylinder block sub-assembly.

  10. REMOVE OIL JET


    1. A01VI07

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