Prior to removing the piston and connecting rod assemblies, ensure the
Cylinder Heads, oil pan, and oil pump pick-up are removed if not already done. Use your fingernail to check for a ridge at the upper limit of ring travel, approximately 1/4-inch down from the top of each cylinder. If ridges are present due to carbon deposits or cylinder wear, they must be completely removed with a special tool according to the manufacturer's instructions, as failure to do so may result in piston breakage. After removing the cylinder ridges, turn the engine upside-down with the
Crankshaft facing up. Before removing the connecting rods, check the side clearance with feeler gauges, sliding them between the first connecting rod and the crankshaft throw until the play is eliminated; the side clearance should not exceed the service limit. If new connecting rods or a new crankshaft are installed, ensure the side clearance meets the specified minimum, and consult an automotive machine shop if machining is necessary. Check the connecting rods and caps for identification marks, and if they are not marked, use a small center punch to create indentations. Loosen each connecting rod cap nut by 1/2-turn until they can be removed by hand, then take off the number one connecting rod cap and bearing insert without dropping the bearing insert. Protect the crankshaft journal and cylinder wall by slipping a short length of plastic or rubber hose over each connecting rod cap bolt as the piston is removed. Remove the bearing insert and push the connecting rod/piston assembly out through the top of the engine using a wooden hammer handle, ensuring all ridges have been removed if resistance is felt. Repeat this process for the remaining cylinders. After removal, reassemble the connecting rod caps and bearing inserts in their respective connecting rods and install the cap nuts finger tight to prevent accidental damage to the bearing surfaces. Avoid separating the pistons from the connecting rods.