Crankshaft And Piston Removal

Crankshaft and Piston Removal

1. Remove the engine/IMA motor/transmission assembly Engine Removal.

2. Remove the IMA motor housing Removal and Replacement.

3. Remove the cam chain Cam Chain Removal.

4. Remove the cylinder head Cylinder Head Removal.

5. Remove the oil strainer (A), then remove the oil pump (B).






6. 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.






7. Remove the bearing cap.

8. Remove the connecting rod caps/bearings. Keep all caps/bearings in order.

9. Lift the crankshaft (A) out of the engine block. Be careful not to damage the journals.





10. Remove the thrust washers (B).

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

12. 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 piston as it is pushed out.






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





14. Reinstall the bearing cap and bearings on the engine block.

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

16. Mark each piston/connecting rod assembly with its cylinder number to make sure they are reinstalled in the original order.

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