Crankshaft and Piston Removal

  1. Remove the baffle plate.

  1. If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer (A). Follow the reamer manufacturer's instructions. If the ridge is not removed, it may damage the pistons as they are pushed out.

  1. Remove the 8 mm bolts.

  1. Remove the bearing cap bolts. To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.

  1. Remove the lower block and bearings. Keep all bearings in order.
  1. Remove the rod caps/bearings. Keep all the caps/bearings in order.

  1. Lift the crankshaft (A) out of the engine. Be careful not to damage the journals and the crankshaft position (CKP) pulse plate (B).
  1. Remove the CKP pulse plate.
  1. Remove the thrust washers (C).
  1. Remove the upper bearing halves from the connecting rods, and set them aside with their respective caps.

  1. Use the wooden handle of a hammer (A) to drive out the pistons (B).
  1. Reinstall the lower block and the bearings on the engine block in the proper order.
  1. Reinstall the connecting rod bearings and caps after removing each piston/connecting rod assembly.
  1. Mark each piston/connecting rod assembly with its cylinder number to make sure they are reused in the original order.
    NOTE: The existing number on the connecting rod does not indicate its position in the engine block, it indicates the rod bore size.