CYLINDER BLOCK DISASSEMBLY


  1. REMOVE PISTON WITH CONNECTING ROD


    1. Remove the piston with connecting rod from the cylinder block.

  2. REMOVE CONNECTING ROD BEARING

  3. REMOVE CYLINDER LINER

    Tech Tips

    Before removing the cylinder liner, put matchmarks on the cylinder liner and cylinder block.

    A01CHQUE06

    Note

    When reusing the cylinder liner, misalignment with the cylinder block may concentrate stress on the thin part of the cylinder liner and the cylinder liner may break.


    1. A01CI1RE01

      Using SST, remove the cylinder liner.

      SST
      S0942-01460

      Tech Tips

      Organize the parts so that each part location can be remembered for reassembly.

  4. REMOVE CRANKSHAFT ASSEMBLY


    1. A01CILUE01

      Remove the 10 bearing cap bolts in the order shown in the illustration.

    2. Using a plastic-faced hammer, tap the bearing caps to remove them.

      Note

      Be careful not to damage the thrust washers and bearings.

    3. Remove the crankshaft.

  5. REMOVE CRANKSHAFT THRUST WASHER SET

    Tech Tips

    Organize the parts so that each part location can be remembered for reassembly.

  6. REMOVE CRANKSHAFT BEARING SET

    Tech Tips

    Organize the parts so that each part location can be remembered for reassembly.

  7. REMOVE REAR CYLINDER BLOCK COVER


    1. A01CGRJ

      Remove the 2 bolts and rear cylinder block cover with O-ring.

  8. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. Remove the bolt and the No. 1 oil nozzle.

  9. REMOVE PISTON RING SET


    1. A01CJHR

      Using a piston ring expander, remove the piston rings.

      Tech Tips

      Arrange the piston rings in the correct order.

  10. REMOVE PISTON PIN HOLE SNAP RING


    1. A01CGZL

      Using snap ring pliers, remove the snap rings.

  11. REMOVE PISTON


    1. A01CITD

      Gradually heat the piston to approximately 50°C (122°F).

    2. A01CIB5

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

      Note

      Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.

  12. REMOVE CONNECTING ROD SMALL END BUSH


    1. A01CI3YE01

      Prepare SST.

      SST
      S0940-21450
      S0948-11130
      S9233-10360

      1. Assemble the guide and press sub-assembly by inserting its pin into the guide, then secure them with the wing nut.

        Tech Tips

        Orient the letter W stamped on the guide above the pin.

      2. A01CIL0E01

        Make sure to align both supporting surfaces of the guide and press sub-assembly flatly on an even plane.

    2. Using SST, remove the bush.


      1. Set the connecting rod assembled without the crankshaft bearing on the guide and press sub-assembly.

      2. A01CHKTE01

        Using SST, install the spindle into the bush.

        SST
        S0940-21470

        Tech Tips

        Align the groove of the spindle with the oil hole of the bush.

      3. A01CIMPE01

        Using a press, remove the bush.

        Tech Tips

        Always operate the press slowly and smoothly.

  13. REMOVE CAMSHAFT BEARING


    1. A01CHRSE01

      Using SST, remove the camshaft bearings in the directions indicated by the arrow marks in the illustration.

      SST
      09215-00101   ( 09215-00130, 09215-00141, 09215-00150, 09215-00161 )
      09215-00013   ( 09215-00021, 09215-00461 )

      Note

      Remove the No. 1, No. 2 and No. 3 camshaft bearings in order.