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Crankshaft and Piston Removal

  1. Remove the transmission:
  1. Remove the crankshaft position (CKP) sensor cover (A), then disconnect the CKP sensor connector (B).
  1. Remove the harness cover (C).

  1. Remove the bearing cap bolts. To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.
  1. Remove the bearing cap bridge.
  1. Remove the rod caps/bearings. Keep all caps/ bearings in order.

  1. Lift crankshaft (A) out of the engine. Be careful not to damage the journals and the CKP pulse plate (B).
  1. Remove the CKP pulse plate.
  1. Remove the upper bearing halves from the connecting rods, and set them aside with their respective caps.

  1. 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.

  1. Use the wooden handle of a hammer (A) to drive out the piston/connecting rod assembly (B). Take care not to damage the cylinder with the connecting rod.
  1. Reinstall the bearing cap bridge and bearings on the engine in the proper order.
  1. Reinstall the connecting rod bearings and caps after removing each piston/connecting rod assembly.
  1. Mark each piston/connecting rod assembly with its cylinder number to make sure they are reused in original order.
    NOTE: The existing number on the connecting rod does not indicate its position in the engine, it indicates the rod bore size.