CYLINDER BLOCK > DISASSEMBLY

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1. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD


    A198034

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



    A198035E02

  1. Using SST, uniformly loosen the 2 bolts.

    SST
    09205-16010  



    A198036

  1. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left.

    HINT:
    Keep the lower bearing inserted in the connecting rod cap.

  1. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

    NOTICE:
    Do not disassemble the piston, piston pin and connecting rod. If the piston pin is removed, the piston, piston pin and connecting rod cannot be reused.

    HINT:
    1. Keep each bearing, connecting rod and cap as a set.
    2. Arrange the piston and connecting rod assemblies in the correct order.



2. REMOVE CONNECTING ROD BEARING

  1. Remove the connecting rod bearings.

    HINT:
    Arrange the removed parts in the correct order.



3. REMOVE PISTON RING SET


    A198037

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

  1. Remove the oil ring and oil ring expander by hand.

    HINT:
    Arrange the removed parts in the correct order.



4. REMOVE CRANKSHAFT


    A198039E01

  1. Uniformly loosen and remove the 10 main bearing cap bolts in the sequence shown in the illustration.



    A198040

  1. Use 2 removed main bearing cap bolts to remove the 5 main bearing caps and 5 lower bearings.

    NOTICE:
    Insert the bolts into the caps in turn. Ease the cap out by gently pulling up and applying force toward the front and back sides of the cylinder block, as shown in the illustration. Take care not to damage the contact surfaces of the cap and cylinder block.

    HINT:
    1. Keep each lower bearing and main bearing cap as a set.
    2. Arrange the main bearing caps in the correct order.



    A198041

  1. Lift out the crankshaft.



5. REMOVE UPPER CRANKSHAFT THRUST WASHER


    A198042

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



6. REMOVE CRANKSHAFT BEARING


    A198044

  1. Remove the 5 upper main bearings from the cylinder block.

    HINT:
    Arrange the bearings in the correct order.



    A198046

  1. Remove the 5 lower main bearings from the 5 main bearing caps.

    HINT:
    Arrange the bearings in the correct order.



7. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY


    A198045

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



8. CLEAN CYLINDER BLOCK

NOTICE:
If the cylinder is washed at high temperature, the cylinder liner will stick out beyond the cylinder block. Always wash the cylinder block at a temperature of 45°C (113°F) or less.