CYLINDER BLOCK DISASSEMBLY

  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 the correct reassembly.

    2. Remove the 2 connecting rod cap bolts.

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

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      Tech Tips

      Keep the lower bearing inserted to the connecting rod cap.

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

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      Text in Illustration
      *1 Ridge Reamer

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

      Tech Tips

      • Keep the bearing, connecting rod and cap together.

      • Arrange the piston and connecting rod assemblies 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. Using a piston ring expander, remove the 2 compression rings.

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      Text in Illustration
      *1 Piston Ring Expander

    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. Check the fitting condition between the piston and piston pin.

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

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

    2. Disconnect the connecting rod from the piston.

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

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

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

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        Tech Tips

        • The piston and piston pin are a matched set.

        • Arrange the pistons, piston pins, piston pin hole snap rings, connecting rods and connecting rod bearings in the correct order.

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

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      Note

      Be careful not to scratch a piston.

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

    5. Using solvent and a brush, thoroughly clean the piston.

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      Note

      Do not use a wire brush.

  5. REMOVE CRANKSHAFT

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

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    2. Uniformly loosen the 16 crankshaft bearing cap bolts, in several steps and in the sequence shown in the illustration.

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

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      Text in Illustration
      *1 Protective Tape
      *2 Cylinder Block
      *3 Bearing Cap
      *a Joint Surface

      Note

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

      • Be careful not to damage the joint surface of the cylinder block and the crankshaft bearing cap.

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

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  8. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

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

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    2. Check the 3 oil nozzles for damage or clogging.

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

  9. CLEAN CYLINDER BLOCK