Cylinder Block: Disassembly

1. Remove the 6 bolts and 2 nuts.
   Fig 1: Locating No. 1 Ventilation Case Bolt

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2. Remove the No. 1 ventilation case by prying between the No. 1 ventilation case and cylinder block with a screwdriver as shown in the illustration.
   NOTE: Be careful not to damage the contact surfaces of the cylinder block and No. 1 ventilation case.

   HINT:

   Tape the screwdriver tip before use.

   Fig 2: Identifying No. 1 Ventilation Case

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1. Using a ridge reamer, remove all the carbon from the top of the cylinder.
   Fig 3: Removing Piston Sub-Assembly With Connecting Rod

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2. Check that the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.

   HINT:

   The matchmarks on the connecting rods and caps are provided to ensure correct reassembly.

   Fig 4: Identifying Matchmarks On Connecting Rod

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3. Using SST, uniformly loosen the 2 bolts.

   SST 09205-16010 

   Fig 5: Tightening Connecting Rods Bolts

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4. 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.

   Fig 6: Removing Connecting Rod Cap

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

   HINT:

   • Keep the bearing, connecting rod and cap as a set.
   • Arrange the piston and connecting rod assemblies in the correct order.

1. Remove the connecting rod bearings.

HINT:

Arrange the removed parts in the correct order.

1. Using a piston ring expander, remove the 2 compression rings.
2. Remove the oil ring rail and oil ring expander by hand.

HINT:

Arrange the removed parts in the correct order.

Fig 7: Removing Piston Ring Set

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1. Using a screwdriver, pry out the 2 snap rings.
   Fig 8: Prying Snap Rings

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2. Gradually heat each piston to approximately 80 to 90°C (176 to 194°F).
   Fig 9: Heating Piston

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

HINT:

• The piston and pin are a matched set.
• Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.

Fig 10: Tapping Piston Pin

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1. Uniformly loosen and remove the 10 main bearing cap bolts in the sequence shown in the illustration.
   Fig 11: Locating Crankshaft Bolt Loosen Sequence

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2. Use 2 removed main bearing cap bolts to remove the 5 main bearing caps and 5 lower bearings.
   NOTE: 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. Be careful to damage the contact surfaces of the cap and cylinder block.
   Fig 12: Removing Main Bearing Cap Bolts

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   HINT:

   • Keep the lower bearing and main bearing cap as a set.
   • Arrange the main bearing caps in the correct order.
3. Lift out the crankshaft.

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

Fig 13: Locating Upper Crankshaft Thrust Washers

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

   HINT:

   Arrange the bearings in the correct order.

   Fig 14: Locating Crankshaft Bearing

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

HINT:

Arrange the bearings in the correct order.

Fig 15: Identifying Lower Main Bearings

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1. Using a 5 mm socket hexagon wrench, remove the bolts and oil nozzles.
   Fig 16: Locating No. 1 Oil Nozzle Sub-Assembly

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