Disassembly [12/2013 - 11/2016]: Procedure

1. Check that the matchmarks on the connecting rod sub-assembly and connecting rod cap are aligned.

   HINT: 

   The matchmarks on the connecting rod sub-assembly and connecting rod cap are guides for correct reassembly.

2. Remove the 2 connecting rod cap bolts.

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   Engine Front

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

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   HINT: 

   Keep the lower connecting rod bearing inserted into the connecting rod cap.

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

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   *a	Ridge Reamer

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

   HINT: 

   • Keep the connecting rod bearing, connecting rod sub-assembly and connecting rod cap together.
   • Arrange the removed parts in the correct order.

HINT: 

Arrange the removed parts in the correct order.

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

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   *a	Piston Ring Expander

2. Remove the oil ring expander and 2 side rails by hand.

   HINT: 

   Arrange the removed parts in the correct order.

1. Check the fitting condition between the piston and piston pin.

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   1. Try to move the piston back and forth on the piston pin.

      If any movement is felt, replace the piston and piston pin as a set.

2. Remove the connecting rod sub-assembly from the piston.

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   1. Using a screwdriver, pry off the piston pin hole snap rings from the piston.
   2. Gradually heat the piston to approximately 80°C (176°F).

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      WARNING:

      Be sure to wear protective gloves.

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

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      HINT: 

      • The piston and piston pin are a matched set.
      • Arrange the removed parts in the correct order.
3. Using a gasket scraper, remove any carbon from the piston top.

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   NOTE:

   Be careful not to scratch a piston.

4. Using a groove cleaning tool or a broken ring, clean the piston ring grooves.

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5. Using solvent and a brush, thoroughly clean the piston.

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   NOTE:

   Do not use a wire brush.

1. Uniformly loosen and remove the 8 crankshaft bearing cap set bolts and 8 seal washers in several steps in the order shown in the illustration.
   Fig 1: Loosening Sequence Of 8 Crankshaft Bearing Cap Set Bolts

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2. Uniformly loosen the 16 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.
   Fig 2: Loosening Sequence Of 16 Crankshaft Bearing Cap Set Bolts

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3. Using a screwdriver, pry out the crankshaft bearing caps. Remove the 4 crankshaft bearing caps and lower crankshaft bearings.

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   *1	Cylinder Block Sub-Assembly
   *2	Crankshaft Bearing Cap
   *a	Protective Tape
   *b	Joint Surface

   NOTE:

   • Push up the crankshaft bearing cap slowly and evenly, alternating from the right and left side so that the crankshaft bearing cap can be removed.
   • Be careful not to damage the contact surfaces of the cylinder block sub-assembly and the crankshaft bearing cap.

   HINT: 

   Tape the screwdriver tip before use.

4. Remove the crankshaft.

1. Remove the upper crankshaft bearings and lower crankshaft bearings.

   HINT: 

   Arrange the removed parts in the correct order.

1. Remove the crankshaft thrust washer set from the cylinder block sub-assembly.

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1. Using a 5 mm hexagon wrench, remove the 3 bolts and 3 No. 1 oil nozzle sub-assemblies.

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2. Check the 3 No. 1 oil nozzle sub-assemblies for damage or clogging.

   If necessary, replace the No. 1 oil nozzle sub-assembly.