CYLINDER BLOCK DISASSEMBLY

PROCEDURE


  1. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    1. Mark each connecting rod cap and piston with a cylinder number.

    2. Turn the crankshaft so that the connecting rod cap can be removed.

    3. A004KLJ

      Using a "TORX" socket wrench E14, remove the 2 connecting rod cap bolts and connecting rod cap.

    4. A004KJ9E03
      Text in Illustration
      *1 Crank pin
      *2 Connecting rod

      Turn the crankshaft and separate the crank pin from the connecting rod.

      Tech Tips

      Turn the crankshaft clockwise when removing the No. 1 or No. 3 piston with connecting rod, and turn it counterclockwise when removing the No. 2 or No. 4 piston with connecting rod.

    5. A004K2I

      Push the connecting rod in the direction of the arrow, and remove the piston with connecting rod from the cylinder block.

  2. REMOVE CYLINDER BLOCK SUB-ASSEMBLY (for Bank 1)

    Note

    Place a cloth to avoid scratching the mating surface of the cylinder block during servicing.


    1. Operate the engine stand so that the bank 1 side faces upward.

    2. A004JWK

      Remove the 5 bolts.

    3. A004IQTE03

      Using a 12 mm socket wrench, loosen the 10 bolts in the order as shown in the illustration.

    4. Remove the 10 bolts and cylinder block (for bank 1).

      Note

      Lift the cylinder block (for bank 1) slightly, and confirm that the crankshaft is remaining on the cylinder block (for bank 2). If the cylinder block (for bank 1) is lifted carelessly when separating, the crankshaft possibly having stuck to cylinder block (for bank 1) may fall off.

  3. REMOVE CRANKSHAFT


    1. A004HAM

      Remove the crankshaft from the cylinder block (for bank 2).

  4. REMOVE REAR ENGINE OIL SEAL


    1. Remove the rear engine oil seal.

  5. REMOVE O-RING


    1. A004JBU

      Remove the O-ring from the cylinder block (for bank 2).

  6. REMOVE CRANKSHAFT BEARING


    1. A004H6SE03
      Text in Illustration
      *1 No. 1 and No. 3 Crankshaft Bearing
      *2 No. 2 and No. 4 Crankshaft Bearing
      *3 No. 5 Crankshaft Bearing
      *a for Bank 1
      *b for Bank 2

      Remove the crankshaft bearings from the cylinder block (for bank 1) and cylinder block (for bank 2).

      Tech Tips


      • Arrange the removed parts in the correct order.

      • Push the bearing at the opposite end to locking lip to remove the bearing.

  7. REMOVE OIL SEPARATOR COVER


    1. A004K1H

      Remove the 7 bolts and oil separator cover from the cylinder block (for bank 1).

  8. REMOVE CYLINDER BLOCK SUB-ASSEMBLY (for Bank 2)


    1. Remove the cylinder block sub-assembly (for bank 2) from the engine stand.

  9. REMOVE CYLINDER BLOCK PLATE


    1. A004I26

      Remove the 5 bolts and cylinder block plate from the cylinder block (for bank 2).

  10. REMOVE CRANKSHAFT SENSOR HOLDER ASSEMBLY


    1. A004IV1

      Remove the 2 bolts and crankshaft sensor holder assembly from the cylinder block (for bank 2).

  11. REMOVE NO. 1 CYLINDER BLOCK TIGHT PLUG


    1. A004JASE01
      Text in Illustration
      *a for Bank 1
      *b for Bank 2

      Remove the 3 No. 1 cylinder block tight plugs from the cylinder block (for bank 1) and cylinder block (for bank 2).

  12. REMOVE CONNECTING ROD BEARING


    1. Remove the connecting rod bearings.

      Tech Tips

      Arrange the removed parts in the correct order.

  13. REMOVE PISTON RING SET

    Tech Tips

    Arrange the removed parts in the correct order.


    1. A004H0C

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

    2. Remove the upper oil ring side rail, lower oil ring side rail and oil ring expander in order by hand.

  14. REMOVE PISTON WITH PIN SUB-ASSEMBLY


    1. A004K4ZE05
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, remove the piston pin hole snap ring on one end from the piston.

      Tech Tips

      Be careful not to damage the piston and piston pin by wrapping the tip of the screwdriver with protective tape.

    2. Remove the piston pin from the piston.

    3. Using a screwdriver with its tip wrapped in protective tape, remove the piston pin hole snap ring on other end from the piston.

      Tech Tips

      Be careful not to damage the piston and piston pin by wrapping the tip of the screwdriver with protective tape.