Piston and Connecting Rod - Removal

REMOVAL





NOTE: Pistons, rings, and rods are serviced as an assembly.

CAUTION: To maintain engine balance, 1, 3, or 4 pistons can be replaced. If 2 pistons are replaced, engine will be out of balance.

1. Remove engine Engine - Removal.
2. Separate engine from transaxle.
3. Mount engine on a suitable engine stand and remove engine lift chain (1).
4. Remove cylinder head Cylinder Head - Removal.




5. Drain engine oil (2).
6. Remove oil pan (1)Engine Oil Pan - Removal.




7. Remove oil filter (1).
8. Remove balance shaft assembly.
9. Remove ladder frame.

NOTE: Remove any carbon build up and clean debris from cylinder prior to piston removal to avoid scratching piston skirts.

10. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation.




11. Rotate crankshaft so that each connecting rod is centered in cylinder bore.
12. Using a permanent ink or paint marker, identify cylinder number on each connecting rod cap.

CAUTION: DO NOT use a number stamp or a punch to mark connecting rods, as damage to connecting rod could occur.

CAUTION: Care must be taken not to damage the fractured rod and cap joint surfaces, as engine damage many occur.

13. Remove connecting rod bolts and cap.

NOTE: Do not reuse connecting rod bolts.

14. Carefully push each piston and rod assembly out of cylinder bore. Re-install bearing cap on the mating rod.
15. Repeat procedure for each piston and connecting rod assembly.