CYLINDER BLOCK(w/o Glow Plug Controller) DISASSEMBLY

PROCEDURE


  1. REMOVE TUBE CONNECTOR


    1. A00YAGA

      Using a 14 mm deep socket wrench, remove the tube connector.

  2. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    1. A00Y59NC03
      *a Matchmark

      Confirm that the matchmarks of the connecting rod and connecting rod cap are aligned.

    2. A00Y89IE02

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

      SST
      09205-16011
    3. A00Y5QD

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

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

      Tech Tips


      • Keep the connecting rod bearing, piston with pin sub-assembly, connecting rod and connecting rod cap together.

      • Keep the piston with pin sub-assembly and connecting rod in the correct order so that they can be returned to their original locations when reassembling.

  3. REMOVE CONNECTING ROD BEARING


    1. Remove the connecting rod bearing from the connecting rod cap.

    2. Remove the connecting rod bearing from the connecting rod.

  4. REMOVE CRANKSHAFT


    1. A00Y5NHE01

      Uniformly loosen the 10 crankshaft bearing cap set bolts in several steps in the order shown in the illustration and remove them.

    2. Remove the 5 crankshaft bearing caps and crankshaft.

  5. REMOVE UPPER CRANKSHAFT THRUST WASHER


    1. A00YBD6

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

  6. REMOVE CRANKSHAFT BEARING


    1. Remove the crankshaft bearing from the crankshaft bearing cap and cylinder block sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

  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 reassembling.


    1. A00Y56J

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

  8. REMOVE PISTON WITH PIN SUB-ASSEMBLY


    1. A00Y59Z

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

      Note

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

  9. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A00Y6IZ

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

  10. REMOVE OIL JET


    1. A00Y793

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