Disassembly

REMOVAL


1. Remove the set plate, then remove the oil pan inner pipe.
2. Remove the oil pan assembly.





3. Remove the rear cover.
4. Remove the oil screen.





5. Remove the oil pump.





6. Remove the bolts and the bearing caps.

CAUTION: To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.

7. Remove the rod caps/bearings and main caps/bearings. Keep all caps/bearings in order.





8. Lift the crankshaft out of the engine, being careful not to damage journals.
9. Remove the upper bearing halves from the connecting rods and set them aside with their respective caps.
10. Reinstall the main caps and bearings on the engine in proper order.





11. If you can feel a ridge of metal or hard carbon around the top of each cylinder, remove it with a ridge reamer. Follow the reamer manufacturer's instructions.

CAUTION: If the ridge is not removed, it may damage the pistons as they are pushed out.





12. Use the wooden handle of a hammer to drive the pistons out.
13. Reinstall the connecting rod bearings and caps after removing each piston/connecting rod assembly.
14. Mark each piston/connecting rod assembly with its cylinder number to avoid mix-up on reassembly.

NOTE: The existing number on the connecting rod does not indicate its position in the engine, it indicates the rod bore size.