Disassembly

Disassembly

1. Remove the drive plate.
2. Remove the knock sensor(A).




3. Remove the upper oil pan(A).




4. Remove the baffle plate(A).




5. Remove the rear oil seal case(A).




6. Remove the oil drain cover(A).




7. Check the connecting rod end play.
8. Check the connecting rod cap oil clearance.
9. Remove the piston and connecting rod assemblies.
(1) Using a ridge reamer, remove all the carbon from the top of the cylinder.
(2) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.

NOTE:
- Keep the bearings, connecting rod and cap together.
- Arrange the piston and connecting rod assemblies in the correct order.

10. Remove the crankshaft main bearing cap and check oil clearance.
11. Check the crankshaft end play.
12. Lift the crankshaft(A) out of engine, being careful not to damage journals.





NOTE:
Arrange the main bearings and thrust bearings in the correct order.

13. Check fit between piston and piston pin.
Try to move the piston back and forth on the piston pin. If any movement is felt, replace piston and piston pin as a set.
14. Remove the piston rings.
(1) Using a piston ring expander, remove the 2 compression rings.
(2) Remove 2 side rails and the spacer by hand.

NOTE:
Arrange the piston rings in the correct order only.

15. Disconnect connecting rod from piston.
Using a press, remove the piston pin from the piston.
(Press-in load : 800 - 1400kg (1764 - 3086lb)