ARMY TM 9-2815-256-24
AIR FORCE TO 38G1-96-2
MARINE CORPS TM 2815-24/5
Remove camshaft, refer to paragraph 3-40.1.
Remove engine front plate and oil bypass valve, refer to paragraphs 3-42.1. and 3-22.1.
Remove crankshaft and main bearings, refer to paragraph 3-43.1.
Remove pistons and liners, refer to paragraph 3-44.1. and 3-44.2.
Remove piston cooling nozzles (13, FIGURE 3-146).
Remove water galley plugs, refer to FIGURE 3-146.
If necessary to place block in hot tank, remove oil galley plugs, refer to FIGURE 3-146.
3-45.2. Piston and Rod.
Discard piston rings and rod bushing. Do not reuse.
Remove piston rings (8, FIGURE 3-143) from piston (9) using piston ring expander. Discard piston rings.
Remove two retaining rings (5) and remove piston pin (6). Discard retaining rings.
Separate piston (7) and rod (4). Keep these parts in place with their respective cylinder liner (9).
INSPECT AND MEASURE.
3-46.1. Pistons-and Cylinder Liners.
Match piston with correct liner and check for scoring (arrows). Wear of this type could be caused by engine
overheating, or foreign material entering cylinder through oiling system. Check for any cracks or other obvious
failures. If any defects are found, replace piston and liner as required. If no defects are found, proceed to next
Visually inspect piston. If piston ring face and ring land have excessive wear, replacement is necessary for both
piston and liner. If no defects are found, proceed to next step.
Compressed air used for cleaning can create airborne particles that may enter the eyes. Pressure
will not exceed 30 psig (207 kPa). Eye protection required.
When washing pistons, always use a stiff bristle brush, not a wire brush, to loosen carbon residue.
Failure to observe this caution could result in damage to pistons.
Clean pistons with hot water and liquid detergent, soak pistons in a 50 percent solution of liquid household
detergent and hot water for 30 to 60 minutes. Use a stiff bristle brush and loosen carbon residue. Dry with
Carefully use a stiff bristle brush to remove all debris and scale from OD of liners. Make certain there are no
nicks or burrs in areas where packings will seat.