CYLINDER BLOCK DISASSEMBLY

PROCEDURE

1. Click here

   REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD

   
   
   1. 

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

   2. 

      Using SST, uniformly loosen the 2 bolts.

      09205-16011

   3. 

      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.

      Tip:

      Keep the lower bearing inserted in the connecting rod cap.

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

      Note:

      Do not disassemble the piston, piston pin and connecting rod. If the piston pin is removed, the piston, piston pin and connecting rod cannot be reused.

      Tip:
      

      • Keep each bearing, connecting rod and cap as a set.

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

2. Click here

   REMOVE CONNECTING ROD BEARING

   
   

   1. Remove the connecting rod bearings.

      Tip:

      Arrange the removed parts in the correct order.

3. Click here

   REMOVE PISTON RING SET

   
   
   1. 

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

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

      Tip:

      Arrange the removed parts in the correct order.

4. Click here

   REMOVE CRANKSHAFT

   
   
   1. 

      Uniformly loosen and remove the 10 main bearing cap bolts in the sequence shown in the illustration.

   2. 

      Use 2 removed main bearing cap bolts to remove the 5 main bearing caps and 5 lower bearings.

      Note:

      Insert the bolts into the caps in turn. Ease the cap out by gently pulling up and applying force toward the front and back sides of the cylinder block, as shown in the illustration. Take care not to damage the contact surfaces of the cap and cylinder block.

      Tip:
      

      • Keep each lower bearing and main bearing cap as a set.

      • Arrange the main bearing caps in the correct order.

   3. 

      Lift out the crankshaft.

5. Click here

   REMOVE UPPER CRANKSHAFT THRUST WASHER

   
   
   1. 

      Remove the upper crankshaft thrust washers from the cylinder block.

6. Click here

   REMOVE CRANKSHAFT BEARING

   
   
   1. 

      Remove the 5 crankshaft bearings (upper) from the cylinder block.

      Tip:

      Arrange the removed parts bearings in the correct order.

   2. 

      Remove the 5 crankshaft bearings (lower) from the 5 crankshaft bearing caps.

      Tip:

      Arrange the removed parts in the correct order.

7. Click here

   REMOVE OIL CHECK VALVE SUB-ASSEMBLY

   
   
   1. 

      Using a magnet hand, remove the oil check valve sub-assembly from the cylinder block.

8. Click here

   REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

   
   
   1. 

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

9. Click here

   REMOVE OIL JET

   
   
   1. 

      Remove the oil jet from the cylinder block.

10. Click here

    CLEAN CYLINDER BLOCK

    Note:

    If the cylinder is washed at high temperature, the cylinder liner will stick out beyond the cylinder block. Always wash the cylinder block at a temperature of 45°C (113°F) or less.