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Pistons and Connecting Rods

REMOVAL

Fig. 1: Example of the cylinder bore ridge

Fig. 2: Using a ridge reamer to remove the cylinder bore ridge will ease removal and installation of the piston and rod assemblies

Fig. 3: Place rubber hose over the connecting rod studs to protect the crank and bores from damage

Fig. 4: Carefully tap the piston out of the bore using a wooden dowel

Fig. 5: Matchmarking the connecting rods to their caps using a scribe

Fig. 6: Matchmarking the connecting rods to their caps using a number stamp — you can also use a center punch and mark the appropriate number of dots on each rod and rod cap

Fig. 7: Always protect the crankshaft journals from scratches and dings — cover the connecting rod bolts with lengths of rubber hose or commercially available rod bolt covers

Fig. 8: Carefully push the piston out with a hammer handle or wooden dowel — never push on the soft bearing that sits in the center of the rod, as this will render it unusable

  1. Remove the engine assembly from the truck, see Engine Removal and Installation.
  2. Remove the intake manifold and cylinder head.
  3. Remove the oil pan.
  4. Remove the oil pump assembly.
  5. Stamp the cylinder number on the machine surfaces of the bolt bosses of the connecting rod and cap for identification when reinstalling. If the pistons are to be removed from the connecting rod, mark the cylinder number on the piston with a silver pencil or quick drying paint for proper cylinder identification and cap-to-rod location.
  6. Examine the cylinder bore above the ring travel. If a ridge exists, remove the ridge with a ridge reamer before attempting to remove the piston and rod assembly. Never cut into the ring travel area in excess of 0.8mm (0.0315 in.) when removing the ridges.
  7. Remove the rod bearing cap and bearing.
  8. Install a guide hose over threads of rod bolts. This is to prevent damage to bearing journal and rod bolt threads.
  9. Remove the rod and piston assembly through the top of the cylinder bore.
  10. Remove the other rod and piston assemblies in the same manner.

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