CYLINDER BLOCK DISASSEMBLY

PROCEDURE


  1. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    1. A005HUB

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

    2. A005J28E02

      Using SST, uniformly loosen the 2 bolts.

      SST
      09205-16010
    3. A005I81

      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.

      Tech Tips

      Keep the lower bearing inserted in the connecting rod cap.

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

      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 bearing, connecting rod and cap as a set.

      • Arrange the piston and connecting rod assemblies in the correct order.

  2. REMOVE CONNECTING ROD BEARING


    1. Remove the connecting rod bearings.

      Tech Tips

      Arrange the removed parts in the correct order.

  3. REMOVE PISTON RING SET


    1. A005KS8

      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. A005GQSE03

      Uniformly loosen and remove the 10 main bearing cap bolts in the sequence shown in the illustration.

    2. A005IY5

      Use 2 removed main bearing cap bolts to remove the 5 main bearing caps and 5 lower bearings.

      Note

      Insert the bolts into the caps in turn. Ease the cap out by gently pulling up and applying force toward the front and back sides of the cylinder block, as shown in the illustration. Take care not to damage the contact surfaces of the cap and cylinder block.

      Tech Tips


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

      • Arrange the main bearing caps in the correct order.

    3. A005HJ6

      Lift out the crankshaft.

  5. REMOVE UPPER CRANKSHAFT THRUST WASHER


    1. A005KC8

      Remove the upper crankshaft thrust washers from the cylinder block.

  6. REMOVE CRANKSHAFT BEARING


    1. A005JU3

      Remove the 5 upper main bearings from the cylinder block.

      Tech Tips

      Arrange the bearings in the correct order.

    2. A005HZC

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

      Tech Tips

      Arrange the bearings in the correct order.

  7. REMOVE OIL CHECK VALVE SUB-ASSEMBLY


    1. A005I68

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

  8. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A005JGG

      Using a 5 mm socket hexagon wrench, remove the bolts and oil nozzles.

  9. REMOVE OIL JET


    1. A005L30

      Remove the oil jet from the cylinder block.

  10. CLEAN CYLINDER BLOCK

    Note

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