ARMY TM 9-2815-260-24
AIR FORCE TO 38G1-126-2
MARINE CORPS TM 09244A/09245A-24
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 (JDE84) with clean
Carefully position piston and connecting rod assembly inside Piston Ring Compressor (JDE84).
Carefully place Piston Ring Compressor (JDE84) 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 piston liner.
Position bearing insert (6) in connecting rod (5) from bottom of cylinder block. Ensure 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). Ensure 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.
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).
Rotate crankshaft several revolutions to insure that engine rotates without excessive tightness.
Measure piston protrusion, refer to paragraph 5.4.5.b(3)(f) and (g).
Check liners for deep scratches caused by improperly installed or broken piston ring.
Check side clearance of connecting rods. Connecting rods must have slight side-to-side
Install oil pump and outlet tube, refer to paragraph 5.4.8.
Install oil pan, refer to paragraph 4.5.3.
Remove capscrews (1, Figure 5-70) and washers (2) that hold down cylinder liners (3).
Ensure that all gasket surfaces are clean and free of foreign material.