Prior to removing the piston and connecting rod assemblies, the
Cylinder Head(s), oil pan, and oil pump must be taken off. Use your fingernail to check for any ridge that may have formed 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, as failure to do so may result in piston breakage. After removing the ridges, turn the engine upside down with the
Crankshaft facing up. Before removing the connecting rods, check the endplay using feeler gauges; if the endplay exceeds the service limit, new connecting rods may be necessary. Ensure that connecting rods and caps are marked for identification, and if not, use a small center-punch to create indentations. Loosen the connecting rod cap nuts gradually until they can be removed by hand, then take off the number one connecting rod cap and bearing insert without dropping the 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. Push the connecting rod/piston assembly out through the top of the engine using a wooden or plastic hammer handle, ensuring all ridge material has been removed. Repeat this process for the remaining cylinders. After removal, reassemble the connecting rod caps and bearing inserts in their respective rods and install the cap nuts finger tight to prevent damage to the bearing surfaces. Avoid separating the pistons from the connecting rods.