Cylinder Block Disassembly

DISASSEMBLY

1. Remove the power steering pump bracket(A) and the knock sensor(B).




2. Remove the air conditioning compressor bracket(A).




3. Remove the lower oil pan(A).









CAUTION:
- Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of 1 arrow.
- After tapping the SST with a plastic hammer along the direction of 2 arrow around more than 2/3 edge of the oil pan, remove it from the ladder frame.
- Do not turn over the SST abruptly without tapping. It be result in damage of the SST.

4. Remove the oil screen(A).




5. Remove the upper oil pan(A).





CAUTION:
- Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of 1 arrow.
- After tapping the SST with a plastic hammer along the direction of 2 arrow around more than 2/3 edge of the oil pan, remove it from the ladder frame.
- Do not turn over the SST abruptly without tapping. It be result in damage of the SST.

6. Check the connecting rod side clearance.
7. Check the connecting rod bearing oil clearance.
8. Remove the piston and connecting rod assemblies.

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

9. Remove the oil pump case.
10. Remove the oil seal case(A).




11. Check the crankshaft end play.
12. Remove the crankshaft bearing cap and check oil clearance.





NOTE:
Arrange the bearings and the bearing caps in order.

13. Lift the crankshaft(A) out of the block, being careful not to damage journals.




14. Remove and arrange the main bearings and thrust bearings in the correct order.




15. Remove the CKP sensor(A).




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

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

18. Disconnect the connecting rod from the piston.
Using a press, remove the piston pin from the piston.
(Press-in load : 2451.7 - 12258.3N(250 - 1250kg, 551.2 - 2755.81lb)