Cylinder Block: Disassembly

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

   HINT:

   The matchmarks on the connecting rods and caps are provided for ensuring the correct reassembly.

   Fig 1: Identifying Matchmarks On Connecting Rod And Cap

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2. Using a 12 mm socket wrench, uniformly loosen and remove the 2 bolts.
3. 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.

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

Fig 2: Locating Connecting Rod Cap Bolts

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HINT:

• Keep the bearing, connecting rod and cap together.
• 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 3: Removing Compression Rings

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1. Using a screwdriver, pry out the 2 snap rings.

Fig 4: Prying Out Snap Rings

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1. Gradually heat the piston to between 80 and 90°C (176 and 194°F).
   Fig 5: Heating Piston

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2. Using a plastic hammer and 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, pin, rings, connecting rods and bearings in the correct order.

1. Uniformly loosen and remove the 10 main bearing cap bolts in the sequence shown in the illustration.
   Fig 7: Identifying Main Bearing Cap Bolts In 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 one of the caps. Ease the cap out by gently pulling up and applying force toward the front and back side of the cylinder block, as shown in the illustration. Take care not to damage the contact surfaces of the cap and cylinder block.

   HINT:

   • Keep the lower bearing and main bearing cap.
     Fig 8: Removing Main Bearing Caps

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   • Arrange the main bearing caps in the correct order.
3. Lift out the crankshaft.

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

Fig 9: Identifying Oil Groove

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1. Remove the 5 crankshaft bearings from the cylinder block.

   HINT:

   Arrange the removed parts in the correct order.

   Fig 10: Identifying Crankshaft Bearings

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1. Remove the 5 No. 2 crankshaft bearings from the 5 main bearing caps.

   HINT:

   Arrange the removed parts in the correct order.

   Fig 11: Identifying Crankshaft Bearings

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