CYLINDER BLOCK DISASSEMBLY

PROCEDURE

  1. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD

    1. A203714

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

    2. A297999

      Remove the 2 connecting rod bolts.

    3. Remove the connecting rod cap with the connecting rod bearing.

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

      Tip:

      Arrange the removed parts in the correct order.

  2. REMOVE CONNECTING ROD BEARING

    1. A164871

      Remove the connecting rod bearings from the connecting rod and connecting rod cap.

      Tip:

      Arrange the removed parts in the correct order.

  3. REMOVE PISTON RING SET

    1. A111311

      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.

      Tip:

      Arrange the removed parts in the correct order.

  4. REMOVE PISTON WITH PIN SUB-ASSEMBLY

    1. A111362

      Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.

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

    2. A111320C01

      *1

      Snap Ring

      Using a screwdriver, pry out the 2 snap rings.

    3. A100988

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

    4. G036556

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

      Tip:

      • The piston and piston pin are a matched set.

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

  5. REMOVE CRANKSHAFT

    1. A207984N03

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

    2. A293320N03

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

    3. A203720C01
      V100135

      Front

      Remove the crankshaft bearing cap by prying between the crankshaft bearing cap and cylinder block sub-assembly with a screwdriver at the areas shown in the illustration.

      Note:

      Do not damage the contacting surfaces of the cylinder block sub-assembly and crankshaft bearing cap.

      Tip:

      • Keep the lower crankshaft bearings and crankshaft bearing cap together.

      • Arrange the upper crankshaft thrust washers in the correct order.

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

      • Tape the screwdriver tip before use.

    4. Remove the crankshaft.

  6. REMOVE UPPER CRANKSHAFT THRUST WASHER

    1. A203723

      Remove the 2 upper crankshaft thrust washers from the cylinder block sub-assembly.

      Tip:

      Arrange the removed parts in the correct order.

  7. REMOVE CRANKSHAFT BEARING

    Tip:

    • Keep the upper and lower crankshaft bearings and crankshaft bearing cap together.

    • Arrange the removed parts in the correct order.

    1. A203722

      Remove the 5 upper crankshaft bearings.

    2. A203721

      Remove the 5 lower crankshaft bearings.

  8. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    1. A129599

      Using a T30 "TORX" socket wrench, remove the 3 bolts and No. 1 crankshaft position sensor plate.

  9. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

    1. A203726

      Using a 5 mm hexagon wrench, remove the 4 bolts and 4 No. 1 oil nozzle sub-assemblies.

  10. REMOVE OIL REFLECTOR PLATE

    1. A203727

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