CYLINDER BLOCK DISASSEMBLY

PROCEDURE


  1. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD


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

    2. A005I3WE01

      Using SST, remove the 8 connecting rod cap bolts and 4 caps.

      SST
      09205-16011

    3. Push the piston, connecting rod sub-assembly and upper bearing through the top of the cylinder block to remove them.

      Tech Tips


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

      • Keep the piston and the connecting rod assemblies in the correct order so that they can be returned to their original locations when reassembled.

  2. REMOVE CONNECTING ROD BEARING


    1. Remove the 8 connecting rod bearings.

  3. REMOVE CRANKSHAFT


    1. A005KVGE01

      Using several steps, loosen and remove the 10 crankshaft bearing cap set bolts uniformly in the sequence shown in the illustration.

    2. Remove the 5 bearing cap and the crankshaft.

  4. REMOVE CRANKSHAFT BEARING


    1. Remove the 10 crankshaft bearings.

  5. REMOVE UPPER CRANKSHAFT THRUST WASHER


    1. Remove the 10 upper crankshaft thrust washer.

  6. REMOVE PISTON RING SET

    Note

    Keep the piston rings in the correct combination and correct order so that they can be returned to their original locations when re-assembling.


    1. A005LOV

      Using a piston ring expander, remove the 2 compression rings.

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

  7. REMOVE PISTON WITH PIN SUB-ASSEMBLY


    1. A005J7PE01
      Text in Illustration
      *1 Connecting Rods
      *2 Piston Pin
      *3 Piston

      Using SST, press the piston pin out of the piston.

      SST
      09221-25026   ( 09221-00021, 09221-00030, 09221-00150, 09221-00090, 09221-00100 )

      Note

      Keep the pistons, pins, rings, connecting rods and bearings in the correct order so that they can be returned to their original locations when reassembled.

  8. REMOVE CONNECTOR TUBE


    1. A005HA3

      Remove the connector tube.

  9. REMOVE STUD BOLT


    1. Using an E5 and E7 "TORX" socket wrench, remove the 7 stud bolts.

  10. REMOVE OIL PUMP SET RING PIN


    1. Remove the 2 oil pump set ring pins.

  11. REMOVE STRAIGHT PIN


    1. Remove the 7 straight pins.

  12. REMOVE OIL JET


    1. Remove the oil jet.