Prior to removing the piston and connecting rod assemblies, the cylinder head(s), oil pan, oil pump pick-up tube, and bearing cap bridge must be taken off. Use your fingernail to check for any ridge at the upper limit of ring travel, approximately 1/4-inch down from the top of each cylinder. If ridges are present due to carbon deposits or cylinder wear, they must be completely removed with a ridge reamer before the pistons are taken out to avoid breakage. Once the ridges are cleared, turn the engine upside-down with the crankshaft facing up. Before removing the connecting rods, check the side clearance with feeler gauges, ensuring the play is eliminated. If the endplay exceeds the service limit, new connecting rods may be necessary, and if new rods or a new crankshaft are installed, the endplay might need to be adjusted. Mark the connecting rods and caps with a center punch to indicate their associated cylinders, as the existing numbers indicate rod bore size. Loosen the connecting rod cap nuts gradually until they can be removed by hand, then take off the number one connecting rod cap and bearing insert without dropping the insert. To protect the crankshaft journal and cylinder wall during piston removal, slip a short length of plastic or rubber hose over each connecting rod cap bolt. Remove the bearing insert and push the connecting rod/piston assembly out through the top of the engine, using a wooden hammer handle to apply pressure on the upper bearing surface. If resistance is encountered, ensure all ridges have been removed. Repeat this process for the remaining cylinders. After removal, reassemble the connecting rod caps and bearing inserts in their respective rods and install the cap nuts finger tight to prevent accidental damage to the bearing surfaces. Avoid separating the pistons from the connecting rods.
