Step 1: Crankcase
Remove shoulder screw from shift arm and retain ing screw from shift rod lever. Slide entire shift linkage assembly from crankcase.
- Shoulder screw
- Shift rod lever retaining screw
Disconnect crankcase recirculating hoses and remove crankcase flange screws.
Remove the upper crankcase head screws.
Remove the lower crankcase head screws.
IMPORTANT: DO NOT remove the four inside retaining screws on the lower crankcase head.
Loosen in stages, and remove the main bearing screws and nuts.
Use the Taper Pin Tool, or equivalent, to push the crankcase taper pins toward intake manifold surface. Do not use any tool smaller than the taper pin bore to remove the pin.
- Tool
- Taper pin
Separate crankcase and cylinder block. It may be necessary to tap on crankshaft with a rawhide or rubber mallet to loosen.
Remove the crankcase from the cylinder block carefully to avoid damaging the crankshaft seal rings.
Step 2: Cylinder Head
Loosen in stages and remove cylinder head retaining screws. Remove the cylinder heads
Step 3: Connecting Rods and Pistons
Use a permanent marker to identify each connecting rod cap, connecting rod, and piston by cylinder number. Number 1 is closest to the flywheel.
Use Torquing Socket, P/N 346187, to loosen in stages the rod cap retaining screws. DO NOT remove the screws.
Using one hand to support the piston, remove the rod cap screws with your other hand. Remove each piston and rod assembly.
IMPORTANT: Reattach each rod cap to its rod as soon as the piston is removed. Each cap is unique and can only be installed on its mated rod. Do not allow rod to contact inside surface of cylinder or crankshaft.
IMPORTANT: Identify all internal components so that if reused, they can be reinstalled in their original positions.
Repeat steps for each remaining piston and connecting rod.
Use an appropriate ring expander to remove all piston rings from pistons. Discard the rings.
Wear safety glasses to avoid injury.
Use Retaining Ring Pliers, or equivalent, to remove wrist pin retaining rings. Discard retaining rings.
Use Wrist Pin Pressing Tool, P/N 396747, to remove wrist pin.
- Driver, P/N 396747
Step 4: Crankshaft
Carefully lift crankshaft straight up and remove from crankcase.
If the lower crankcase head is to be resealed or the lower main bearing replaced, remove the four bearing retainer screws. While rotating the crank case head, gently tap on the flange and remove the head.
- Bearing retaining screws
To remove the lower crankshaft seal, use a drift punch. Remove and discard two crankcase head O-rings.
- Drift punch
Remove the O-ring from crankshaft sleeve and inspect it. Replace the O-ring if it is not in good condition.
Inspect the crankshaft sleeve and replace, if necessary. To remove the sleeve, use Slide Hammer, P/N 432128, and Large Puller Jaws, P/N 432129.
Remove the lower main bearing only if it needs **to be replaced. Use external retaining ring pliers to remove the lower main bearing retaining ring.
Using an appropriate bearing separator, support the bearing, place separator flats against the bearing, and press it off the crankshaft.
IMPORTANT: If the lower main bearing is removed from the crankshaft, it must be dis carded. DO NOT reuse it.
Use a drift punch to remove the upper crankshaft seal. Remove and discard two crankcase head
Remove and inspect crankcase seal rings. Identify each ring for installation in original location.
Remove center main bearings and split sleeves for inspection. DO NOT mix parts. Note location of bearings for reassembly.
