ARMY TM 9-2815-259-24
AIR FORCE TO 38G1-125-2
MARINE CORPS 09249A/09246A-24
Inspect piston pin as follows:
Piston pin has a highly polished surface. Do not attempt to polish or
refinish piston pin. Failure to comply could result in excessive piston wear.
Visually inspect piston pin for wear or damage. Replace piston pin if worn or
damage is observed.
Measure piston pin outer diameter using outer diameter micrometer. Piston pin outer
diameter should be 1.6243 - 1.6252 in. (41.257 - 41.280 mm). Replace piston pin if
measurement is out of specifications.
Dip piston pin in clean engine oil.
Install piston pin through piston. Piston pin should pass through piston using only
light thumb pressure.
Insert piston pin from both sides. If piston pin enters freely, but binds in the center,
replace piston and cylinder liner, refer to paragraph 5.4.6, as a set.
Insert piston pin to check for bore alignment. If piston pin clicks or needs to be
forced into bore on opposite side, replace piston and cylinder liner, refer to paragraph
5.4.6, as a matched set.
Inspect connecting rod as follows:
Inspect rod bearings for damage. Replace rod bearings if damage is observed.
Measure and record crankshaft (7, Figure 5-67) journal outer diameter at several
points. Compare crankshaft journal outer diameter with specifications given in Table
5-6. Replace crankshaft (7) if out of specifications.
Table 5-6. Connecting Rod Journal and Bearing Specifications.
Crankshaft Journal OD
3.0629 - 3.0640 in. (77.800 - 77.826 mm)
Assembled Rod Bearing ID
3.0659 - 3.0679 in. (77.876 - 77.927 mm)
Oil Clearance (new parts)
0.0020 - 0.0050 in. (0.050 - 0.127 mm)
Oil Clearance (used parts)
0.0020 - 0.0600 in. (0.050 - 0.152 mm)
Assemble connecting rod (5, Figure 5-72), cap (2), and bearings (3 and 6) using old
capscrews (1). Torque capscrews to 50 lb-ft (68 Nm). Tighten capscrews an
additional 90 degrees (1/4 turn).