Removal

1. Drain engine cooling system.
2. Remove upper intake manifold.
3. Remove lower intake manifold.
4. Remove cylinder heads.
5. Remove oil pan.
6. Remove oil pump and oil pump intermediate shaft.
7. Before removing the piston, inspect the top of each cylinder bore. If a ridge has formed at the top of the cylinder it must be removed before the piston is removed. Remove ridge as follows:
a. Turn crankshaft until the piston to be removed is at the bottom of cylinder bore.
b. Place a clean shop cloth over the piston head to collect cuttings.
c. Remove ridge using Cylinder Ridge Reamer T64L-6011-EA or equivalent. Never cut into the ring travel area more than 0.794 mm (1/32 inch) when removing the ridge.

8. Turn crankshaft until the piston to be removed is at the lowest point of its travel. If more than one piston is being removed, identify the pistons and connecting rod caps. Each component should be installed in its original position during assembly.
9. Remove connecting rod cap retaining nuts and cap.

NOTE: The cylinder number is stamped on the top of the piston. Matched letters are stamped on the sides of corresponding connecting rod and cap.

10. Install a 50 mm (2 inch) piece of 3/8-inch fuel hose (or similar protector) over connecting rod cap studs and push piston out through top of the cylinder bore.

CAUTION: Use care to prevent damage to bearing surfaces or possible engine damage may occur.

11. Install connecting rod cap and hold in position with cap retaining nuts.
12. Inspect cylinder bore. If new piston rings are to be installed on the piston, a visible cross-hatch pattern should be obvious on cylinder bore wall.
13. If honing is required, remove glaze from cylinder wall using spring-loaded hone. Follow manufacturer's instructions when using this type of equipment. After honing, thoroughly clean cylinder bore using a detergent and water solution.