CYLINDER BLOCK DISASSEMBLY

PROCEDURE


  1. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    1. Check that the matchmarks on the connecting rod sub-assembly and connecting rod cap are aligned.

      Tech Tips

      The matchmarks on the connecting rod sub-assembly and connecting rod cap are guides for correct reassembly.

    2. A002AVTC01
      B003Z8F Engine Front

      Remove the 2 connecting rod cap bolts.

    3. A002AIB

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

      Tech Tips

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

    4. A0028Y3C05
      *a Ridge Reamer

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

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

      Tech Tips


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

      • Arrange the removed parts in the correct order.

  2. REMOVE CONNECTING ROD BEARING

    Tech Tips

    Arrange the removed parts in the correct order.

  3. REMOVE PISTON RING SET


    1. A0026W2C03
      *a Piston Ring Expander

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

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

      Tech Tips

      Arrange the removed parts in the correct order.

  4. REMOVE PISTON


    1. A0029PC

      Check the fitting condition between the piston and piston pin.


      1. Try to move the piston back and forth on the piston pin.

        If any movement is felt, replace the piston and piston pin as a set.

    2. A002A3P

      Remove the connecting rod sub-assembly from the piston.


      1. Using a screwdriver, pry off the piston pin hole snap rings from the piston.

      2. A002BPD

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

        CAUTION:

        Be sure to wear protective gloves.

      3. A002A60

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

        Tech Tips


        • The piston and piston pin are a matched set.

        • Arrange the removed parts in the correct order.

    3. A0028BB

      Using a gasket scraper, remove any carbon from the piston top.

      Note

      Be careful not to scratch a piston.

    4. A0029AN

      Using a groove cleaning tool or a broken ring, clean the piston ring grooves.

    5. A002C74

      Using solvent and a brush, thoroughly clean the piston.

      Note

      Do not use a wire brush.

  5. REMOVE CRANKSHAFT


    1. A0028UTN01

      Uniformly loosen and remove the 8 crankshaft bearing cap set bolts and 8 seal washers in several steps in the order shown in the illustration.

    2. A002BCAN02

      Uniformly loosen the 16 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.

    3. A002ADLC12
      *1 Cylinder Block Sub-Assembly
      *2 Crankshaft Bearing Cap
      *a Protective Tape
      *b Joint Surface

      Using a screwdriver, pry out the crankshaft bearing caps. Remove the 4 crankshaft bearing caps and lower crankshaft bearings.

      Note


      • Push up the crankshaft bearing cap slowly and evenly, alternating from the right and left side so that the crankshaft bearing cap can be removed.

      • Be careful not to damage the contact surfaces of the cylinder block sub-assembly and the crankshaft bearing cap.

      Tech Tips

      Tape the screwdriver tip before use.

    4. Remove the crankshaft.

  6. REMOVE CRANKSHAFT BEARING


    1. Remove the upper crankshaft bearings and lower crankshaft bearings.

      Tech Tips

      Arrange the removed parts in the correct order.

  7. REMOVE CRANKSHAFT THRUST WASHER SET


    1. A0029FC

      Remove the crankshaft thrust washer set from the cylinder block sub-assembly.

  8. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A0029UN

      Using a 5 mm hexagon wrench, remove the 3 bolts and 3 No. 1 oil nozzle sub-assemblies.

    2. Check the 3 No. 1 oil nozzle sub-assemblies for damage or clogging.

      If necessary, replace the No. 1 oil nozzle sub-assembly.

  9. CLEAN CYLINDER BLOCK SUB-ASSEMBLY