Disassembly [03/2019 - 09/2022]: Procedure

HINT: 

There are 2 installation methods for the No. 1 ventilation case.

Depending on the installation method, the number of bolts, nuts and stud bolts used will vary.

1. Type A:
   1. Remove the 6 bolts and 2 nuts.

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2. Type B:
   1. Remove the 8 bolts.

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3. Remove the No. 1 ventilation case by prying between the No. 1 ventilation case and cylinder block sub-assembly with a screwdriver with its tip wrapped with protective tape.

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   *a	Protective Tape

   NOTE:

   Be careful not to damage the contact surfaces of the cylinder block sub-assembly and No. 1 ventilation case.

1. Place a paint mark across each corresponding connecting rod and connecting rod cap.

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   *a	Paint Mark

   HINT: 

   The paint marks are used to ensure that the same parts are installed in the same combination to their original locations.

2. Using SST, remove the 8 connecting rod bolts from the connecting rod caps.

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   • SST: 09205-16011 
3. Using the 2 removed connecting rod bolts, remove the 4 connecting rod caps with connecting rod bearings by wiggling each connecting rod cap left and right.

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   HINT: 

   Keep the connecting rod bearing installed to the connecting rod cap.

4. Using a ridge reamer, scrape off any carbon on the top of the cylinder.

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5. Push out the 4 pistons with 4 connecting rods and 4 connecting rod bearings through the top of the cylinder block sub-assembly.

   HINT: 

   • Keep the connecting rod bearings, connecting rods and connecting rod caps together.
   • Arrange the removed parts in such a way that they can be reinstalled to their original locations.

1. Remove the 8 connecting rod bearings from the 4 connecting rods and 4 connecting rod caps.

   HINT: 

   Arrange the removed parts in such a way that they can be reinstalled to their original locations.

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

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2. Remove the oil ring expander, upper side rail and lower side rail from the piston by hand.

   HINT: 

   Arrange the removed parts in such a way that they can be reinstalled to their original locations.

1. Using a screwdriver, pry out the piston pin hole snap ring from the piston.

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   NOTE:

   • Do not remove the piston pin hole snap ring (rear side) unless it is being replaced.
   • Be careful not to damage the piston when removing the piston pin hole snap ring (rear side).
2. Gradually heat each piston to approximately 80 to 90°C (176 to 194°F).

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   WARNING:

   Be sure to wear protective gloves.

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

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   HINT: 

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

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

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2. Using the 2 removed crankshaft bearing cap set bolts, remove the 5 crankshaft bearing caps from the cylinder block sub-assembly by wiggling each crankshaft bearing cap back and forth.

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   HINT: 

   Arrange the removed parts in such a way that they can be reinstalled to their original locations.

3. Remove the crankshaft from the cylinder block sub-assembly.

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

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1. Remove the 5 upper crankshaft bearings from the cylinder block sub-assembly.

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   HINT: 

   Arrange the removed parts in such a way that they can be reinstalled to their original locations.

2. Remove the 5 crankshaft bearings from the 5 crankshaft bearing caps.

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   HINT: 

   Arrange the removed parts in such a way that they can be reinstalled to their original locations.

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

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