CYLINDER BLOCK DISASSEMBLY

PROCEDURE


  1. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. A01M21W

      Remove the cylinder block water jacket spacer from the cylinder block sub-assembly.

  2. REMOVE NO. 1 VENTILATION CASE


    1. A01LWWH

      Remove the 6 bolts and 2 nuts.

    2. A01LXLPC01
      *a Protective Tape

      Remove the No. 1 ventilation case by prying between the No. 1 ventilation case and cylinder block sub-assembly with a screwdriver with its tip wrapped with protective tape.

      Note

      Be careful not to damage the contact surfaces of the cylinder block sub-assembly and No. 1 ventilation case.

    3. A01M02X

      Remove the 2 oil separator gaskets from the case separator.

    4. A01LZ9H

      Remove the 2 bolts and case separator from the No. 1 ventilation case.

  3. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    1. A01M1B8C01
      *a Paint Mark

      Place a paint mark across each corresponding connecting rod and connecting rod bearing cap.

      Tech Tips

      The paint marks are used to ensure that the same parts are installed in the same combination to their original locations.

    2. A01LX8AN01

      Using SST, remove the 8 connecting rod bolts from the connecting rod bearing caps.

      SST
      09205-16011
    3. A01LVRK

      Using the 2 removed connecting rod bolts, remove the 4 connecting rod bearing caps with lower connecting rod bearings by wiggling each connecting rod cap back and forth.

      Tech Tips

      Keep the lower connecting rod bearing installed to the connecting rod cap.

    4. Push out the 4 piston sub-assembly with pins with connecting rods and connecting rod bearings through the top of the cylinder block sub-assembly.

      Tech Tips


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

      • Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  4. REMOVE CONNECTING ROD BEARING


    1. Remove the 8 connecting rod bearings from the 4 connecting rods and 4 connecting rod bearing caps.

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  5. REMOVE CRANKSHAFT


    1. A01M0KGN01

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

    2. A01LVT2

      Using the 2 removed crankshaft bearing cap set bolts, remove the 5 No. 1 crankshaft bearing caps from the cylinder block sub-assembly by wigging each crankshaft bearing cap back and forth.

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

    3. Remove the crankshaft from the cylinder block sub-assembly.

  6. REMOVE CRANKSHAFT BEARING


    1. A01LY3L

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

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

    2. A01LZ3W

      Remove the 5 lower crankshaft bearings from the 5 No. 1 crankshaft bearing caps.

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  7. REMOVE UPPER CRANKSHAFT THRUST WASHER


    1. A01LX6K

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

  8. REMOVE PISTON RING SET


    1. A01M306

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

    2. Remove the oil ring expander, upper side rail and lower side rail from the piston by hand.

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  9. REMOVE PISTON SUB-ASSEMBLY WITH PIN


    1. A01LVYN

      Using a screwdriver, pry out the piston pin hole snap ring from the piston.

      Note


      • Do not remove the piston pin hole snap ring (rear side) unless it is being replaced.

      • Be careful not to damage the piston when removing the piston pin hole snap ring (rear side).

    2. A01M00J

      Gradually heat the piston to approximately 80°C (176°F).

      CAUTION:

      Be sure to wear protective gloves.

    3. A01LXOW

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

      Tech Tips


      • The piston and piston pin are a matched set.

      • Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  10. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A01LYUU

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