Crankshaft and Piston Removal

Crankshaft and Piston Removal

1. Remove the engine/transmission. Engine Removal

2. Remove the transmission. Manual Transmission Removal

3. Remove the pressure plate, Service and Repair the clutch disc, Service and Repair and the flywheel. Service and Repair

4. Remove the oil pan. Engine Oil Pan Removal

5. Remove the oil pump. Service and Repair

6. Remove the cylinder head. Cylinder Head Removal

7. Remove the baffle plates.






8. Remove the 8 mm bolts in sequence.






9. Remove the bearing cap bolts. To prevent warpage, loosen the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.






10. Remove the lower block and the bearings. Keep all the bearings in order.

11. Remove the connecting rod caps/bearing halves. Keep all connecting rod caps/bearing halves in order.






12. Lift the crankshaft out of the engine. Be careful not to damage the journals.

13. Remove the upper bearing halves from the connecting rods, and set them aside with their respective caps.






14. If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer (A). Follow the reamer manufacturer's instructions. If the ridge is not removed, it may damage the pistons as they are pushed out.






15. Use the wooden handle of a hammer (A) to drive out the piston/connecting rod assembly (B).

16. Reinstall the lower block and the bearings on the engine in the proper order.

17. Reinstall the connecting rod bearings and the caps after removing each piston/connecting rod assembly.

18. Mark each piston/connecting rod assembly with its cylinder number to make sure they are reused in the original order.
NOTE: The existing number on the connecting rod does not indicate its position in the engine, it indicates the rod bore size.