CYLINDER BLOCK DISASSEMBLY

PROCEDURE


  1. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    1. A004U8C

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

    2. A004NVT

      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.

      Tech Tips

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

  2. REMOVE CONNECTING ROD BEARING


    1. A004OI5

      Remove the connecting rod and connecting rod cap bearings.

      Tech Tips

      Arrange the removed parts in the correct order.

  3. REMOVE PISTON RING SET

    Tech Tips

    Arrange the piston rings in the correct order.


    1. A004OGW

      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.

  4. REMOVE PISTON WITH PIN SUB-ASSEMBLY


    1. A004RB5

      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. A004RICE06
      Text in Illustration
      *1 Snap Ring

      Using a screwdriver, pry out the 2 snap rings.

    3. A004QAB

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

    4. A004SPG

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

      Tech Tips


      • The piston and pin are a matched set.

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

  5. REMOVE CRANKSHAFT


    1. A004RCXE01

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

    2. A004TV2E01

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

    3. A004TYIE01
      *1 Front

      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.

      Tech Tips


      • Keep the lower bearings and crankshaft bearing caps 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.

  6. REMOVE UPPER CRANKSHAFT THRUST WASHER


    1. A004NBF

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

      Tech Tips

      Arrange the thrust washers in the correct order.

  7. REMOVE CRANKSHAFT BEARING

    Tech Tips


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


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


    1. A004RU2

      Remove the 5 upper crankshaft bearings.

    2. A004NB1

      Remove the 5 lower crankshaft bearings.

  8. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A004N56

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

  9. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A004NJM

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

  10. REMOVE OIL REFLECTOR PLATE


    1. A004RA8

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