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CYLINDER BLOCK DISASSEMBLY

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  1. Click here

    REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    1. A01IOFV

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

    2. A01IOED

      Remove the 2 connecting rod bolts.

    3. Remove the connecting rod cap with bearing.

    4. Push out the piston and connecting rod with bearing through the top of the cylinder block to remove them.

      Tip:

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

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    REMOVE CONNECTING ROD BEARING


    1. A01IRH3

      Remove the connecting rod and connecting rod cap bearings.

      Tip:

      Arrange the removed parts in the correct order.

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    REMOVE PISTON RING SET

    Tip:

    Arrange the piston rings in the correct order.


    1. A01IRN8

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

    2. Using a piston ring expander, remove the oil ring rail.

    3. Remove the oil ring expander by hand.

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    REMOVE PISTON WITH PIN SUB-ASSEMBLY


    1. A01IOUV

      Check the fitting condition between the piston and piston pin by trying 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. A01IOHAE06

      Using a screwdriver, pry out the 2 snap rings.

      Table 1. Text in Illustration
      *1 Snap Ring
    3. A01IS2C

      Gradually heat the piston to 80 to 90°C (176 to 194°F).

    4. A01IQ8BE01

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

      Tip:

      • The piston and pin are a matched set.

      • Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.

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    REMOVE CRANKSHAFT


    1. A01IQ0NE01

      Uniformly loosen and remove the 10 bolts in several steps, in the sequence shown in the illustration.

    2. A01IN82E01

      Uniformly loosen and remove the 10 bearing cap bolts in several steps, in the sequence shown in the illustration.

    3. A01IQZLE01

      Remove the crankshaft bearing cap by prying between the crankshaft bearing cap and cylinder block with a screwdriver.

      Note:

      Do not damage the contact surfaces of the cylinder block and crankshaft bearing cap.

      Tip:

      • Keep the lower bearings and crankshaft bearing cap together.

      • Arrange the thrust washers in the correct order.

      • Keep the upper crankshaft bearings and upper crankshaft thrust washers together with the cylinder block.

      • Tape the screwdriver tip before use.

    4. Remove the crankshaft.

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    REMOVE UPPER CRANKSHAFT THRUST WASHER


    1. A01IT25

      Remove the 2 upper crankshaft thrust washers from the cylinder block.

      Tip:

      Arrange the thrust washers in the correct order.

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    REMOVE CRANKSHAFT BEARING

    Tip:

    • Keep the upper and lower crankshaft bearing and crankshaft bearing cap as a set.


    • Arrange the crankshaft bearing cap and bearings in the correct order.


    1. A01IR7I

      Remove the 5 upper crankshaft bearings.

    2. A01INVM

      Remove the 5 lower crankshaft bearings.

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    REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A01IO5N

      Using a T30 "TORX" socket wrench, remove the 3 bolts and sensor plate.

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    REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A01ISX2

      Using a 5 mm hexagon wrench, remove the 4 bolts and 4 oil nozzles.

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    REMOVE OIL REFLECTOR PLATE


    1. A01IR3W

      Using a 5 mm hexagon wrench, remove the 3 bolts and 3 oil reflector plates.