1. | Remove the cam chain. |
2. | Remove the cylinder head. |
3. | Remove the oil screen (A), then remove the oil pump (B).
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4. | 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.
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5. | Remove the bearing cap bridge. |
6. | Remove the rod caps/bearings. Keep all caps/bearings in order. |
7. | Lift crankshaft out of the cylinder block, bearing careful not to damage the journals.
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8. | Remove the upper bearing halves from the connecting rods, and set them aside with their respective caps. |
9. | 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.
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10. | Use the wooden handle of a hammer (A) to drive out the pistons (B).
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11. | Reinstall the bearing cap bridge and bearings on the cylinder block. |
12. | Reinstall the connecting rod bearings and caps after removing each piston/connecting rod assembly. |
13. | To avoid mixup on reassembly, mark each piston/connecting rod assembly with its cylinder number. NOTE: The existing number on the connecting rod does not indicate its position in the block, it indicates the rod bore size. |