Piston and Connecting Rod Assembly

Removal

PROCEDURE

1. Remove the cylinder head and oil pan.

2. If a ridge has formed at the top of the cylinders, remove it with a reamer or scraper without damaging the cylinder wall. A ridge indicates excessive cylinder wear.

3. The connecting rod and connecting rod cap must be stamped with the number of the cylinder to which the rod belongs. Cylinder No. 1 is located on the timing chain cover side. If the numbers are not visible, mark them with paint or punch them. Marks must be made on the machined side surface of the rod and cap.

4. Turn the crankshaft and set the pistons of cylinders 1 and 4 to top dead center (TDC).

5. Remove the nuts from the connecting rod cap of cylinder 1. Remove the cap and take out the lower connecting rod bearing shell. If the shell will be reinstalled, tape it to the removed cap.

6. To avoid damaging the crankshaft connecting rod journals, wrap tape over the threads of the connecting rod cap bolts.

7. Using the handle of a hammer, push the piston into the cylinder and remove the piston through the top of the cylinder block. Remove the upper connecting rod bearing shell and tape it to the removed connecting rod.

8. Install the cap on the connecting rod and secure it with the nuts to preserve the original assembly order of the parts.

9. Repeat the above operations to remove the connecting rod with the piston of No. 4 cylinder.

10. Turn the crankshaft 180° and set the pistons of cylinders 2 and 3 to TDC. Remove the connecting rods with pistons from these cylinders.