CYLINDER BLOCK(w/o Glow Plug Controller) DISASSEMBLY

PROCEDURE

  1. REMOVE TUBE CONNECTOR

    1. A286923

      Using a 14 mm deep socket wrench, remove the tube connector.

  2. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD

    1. A200010C03

      *a

      Matchmark

      Confirm that the matchmarks of the connecting rod and connecting rod cap are aligned.

    2. A198448E02

      Using SST, remove the connecting rod bolts and connecting rod caps.

      09205-16011

    3. A198449

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

    4. Push the piston with pin sub-assembly, connecting rod and connecting rod bearing through the top of the cylinder block sub-assembly.

      Tip:

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

      • Keep the piston with pin sub-assembly and connecting rod in the correct order so that they can be returned to their original locations when reassembling.

  3. REMOVE CONNECTING ROD BEARING

    1. Remove the connecting rod bearing from the connecting rod cap.

    2. Remove the connecting rod bearing from the connecting rod.

  4. REMOVE CRANKSHAFT

    1. A286924E01

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

    2. Remove the 5 crankshaft bearing caps and crankshaft.

  5. REMOVE UPPER CRANKSHAFT THRUST WASHER

    1. A198475

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

  6. REMOVE CRANKSHAFT BEARING

    1. Remove the crankshaft bearing from the crankshaft bearing cap and cylinder block sub-assembly.

      Tip:

      Arrange the removed parts in the correct order.

  7. REMOVE PISTON RING SET

    Tip:

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

    1. A067951

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

  8. REMOVE PISTON WITH PIN SUB-ASSEMBLY

    1. A198456

      Using a screwdriver, pry out the snap ring and remove the piston pin.

      Note:

      Do not change the combination of the pistons and piston pins.

  9. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

    1. A198451

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

  10. REMOVE OIL JET

    1. A198452

      Remove the oil jet from the cylinder block sub-assembly.