CYLINDER BLOCK DISASSEMBLY

PROCEDURE


  1. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    1. A00Y5SY

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

    2. A00Y4V9N04

      Using SST, uniformly loosen the 2 connecting rod bolts.

      SST
      09205-16010
    3. A00Y7SO

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

      Tech Tips

      Keep the lower connecting rod bearing inserted in the connecting rod cap.

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

      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.

      Tech Tips


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

      • Arrange the removed parts in the correct order.

  2. REMOVE CONNECTING ROD BEARING


    1. Remove the connecting rod bearings from the connecting rod cap and connecting rod.

      Tech Tips

      Arrange the removed parts in the correct order.

  3. REMOVE PISTON RING SET


    1. A00YAN4

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

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

      Tech Tips

      Arrange the removed parts in the correct order.

  4. REMOVE CRANKSHAFT


    1. A00Y4XSN07

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

    2. A00Y9SR

      Using the 2 removed crankshaft bearing cap set bolts, remove the 5 crankshaft bearing caps and 5 lower crankshaft bearings.

      Note

      Insert the crankshaft bearing cap set bolts into the crankshaft bearing caps in turn. Ease the crankshaft bearing cap out by gently pulling it up while wiggling it back and forth, as shown in the illustration. Be careful not to damage the contact surfaces of the crankshaft bearing cap and cylinder block sub-assembly.

      Tech Tips


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

      • Arrange the crankshaft bearing caps in the correct order.

    3. A00Y9XW

      Remove the crankshaft.

  5. REMOVE UPPER CRANKSHAFT THRUST WASHER


    1. A00Y9HY

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

  6. REMOVE CRANKSHAFT BEARING


    1. A00YABU

      Remove the 5 upper crankshaft bearings from the cylinder block sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

    2. A00Y54G

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

      Tech Tips

      Arrange the removed parts in the correct order.

  7. REMOVE OIL CHECK VALVE SUB-ASSEMBLY


    1. A00YBEX

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

  8. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A00Y8FD

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

  9. REMOVE OIL JET


    1. A00Y7JJ

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

  10. CLEAN CYLINDER BLOCK SUB-ASSEMBLY

    Note

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