CYLINDER BLOCK DISASSEMBLY

PROCEDURE


  1. REMOVE CYLINDER BLOCK WATER JACKET SPACER


    1. B006MPO

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

  2. 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. B006OMNC01
      B006LKF Front of Engine

      Remove the 2 connecting rod bolts.

    3. B006LOG

      Using the 2 removed connecting rod 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 installed to the connecting rod cap.

    4. B006NE1C01
      *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 such a way that they can be reinstalled to their original locations.

  3. REMOVE CONNECTING ROD BEARING


    1. Remove the connecting rod bearings from the connecting rod sub-assembly and connecting rod cap.

      Tech Tips

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

  4. REMOVE PISTON RING SET


    1. B006KQ0C01
      *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 such a way that they can be reinstalled to their original locations.

  5. REMOVE PISTON


    1. B006QSO

      Check the fitting condition between the piston and piston pin.


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

        Tech Tips

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

    2. B006LFC

      Remove the connecting rod sub-assembly from the piston.


      1. Using a screwdriver, pry out the piston pin hole snap ring (front side).

        Note


        • Do not remove the piston pin hole snap ring (rear side) unless it has to be replaced.

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

      2. B006MA3

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

        CAUTION:

        Be sure to wear protective gloves.

      3. B006NMV

        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 such a way that they can be reinstalled to their original locations.

    3. B006P0W

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

      Note

      Be careful not to scratch the piston.

    4. B006LXF

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

    5. B006QR1

      Using solvent and a brush, thoroughly clean the piston.

      Note

      Do not use a wire brush.

  6. REMOVE CRANKSHAFT


    1. B006OHFN01

      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. B006PZVN01

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

    3. B006KSZC01
      *1 Cylinder Block Sub-assembly
      *2 Crankshaft Bearing Cap
      *a Protective Tape
      *b Contact Surface

      Using a screwdriver with its tip wrapped with protective tape, pry out the 4 crankshaft bearing caps. Remove the 4 crankshaft bearing caps and 4 lower crankshaft bearings as a set.

      Note


      • Push up the crankshaft bearing cap slowly and evenly, alternating between 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.

    4. Remove the crankshaft.

  7. REMOVE CRANKSHAFT BEARING


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

      Tech Tips

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

  8. REMOVE CRANKSHAFT THRUST WASHER SET


    1. B006KKL

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

  9. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. B006NLE

      Using a 5 mm hexagon socket 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.

      Tech Tips

      If there is damage or clogs, replace the No. 1 oil nozzle sub-assembly.