ARMY TM 9-2815-259-24
AIR FORCE TO 38G1-125-2
MARINE CORPS 09249A/09246A-24
If piston protrusion is out of specifications, check dimensions of piston, cylinder block,
crankshaft, and bearings to determine the cause.
Assemble piston assembly, refer to paragraph d.
Remove all covering installed during step a (14).
Coat piston (4, Figure 5-72), piston liner (11), and Piston Ring Compressor with clean engine oil.
Carefully position piston and connecting rod assembly inside Piston Ring Compressor.
Carefully place Piston Ring Compressor with piston and connecting rod over piston liner so the
word FRONT on side of rod and on side of piston faces toward front of engine. Push piston into
Position bearing insert (6) in connecting rod (5) from bottom of cylinder block. Insure that tang of
bearing insert is firmly seated in groove of connecting rod.
Apply clean engine oil to bearing insert (6) and crankshaft journal. Carefully pull connecting rod
(5) and bearing insert against crankshaft journal.
Install bearing insert (3) in cap (2). Insure that tang of bearing insert is firmly seated in groove of
Apply clean engine oil to bearing insert (3). Install cap (2) on connecting rod (5) with tangs to
Always use new capscrews for final assembly of connecting rod and cap. If
capscrews have been tightened before, do not reuse for final assembly.
Failure to comply could result in engine failure.
(10) Dip new capscrews (1) in clean engine oil. Install capscrews and torque evenly to 43 lb-ft (58
Nm). Tighten capscrews an additional 90 degrees (1/4 turn).
(11) Rotate crankshaft several revolutions to insure that engine rotates without excessive tightness.
(12) Measure piston protrusion, refer to paragraph 5.4.5.b(3)(f) and (g).
(13) Check liners for deep scratches caused by improperly installed or broken piston ring.
(14) Check side clearance of connecting rods. Connecting rods must have slight side-to-side
(15) Install oil pump and outlet tube, refer to paragraph 5.4.9.
(16) Install oil pan, refer to paragraph 4.5.3.
(17) Remove capscrews (1, Figure 5-70) and washers (2) that hold down cylinder liners (3).