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ARMY TM 9-2815-253-24 AIR FORCE TO 38G1-93-2 MARINE CORPS TM 2815-24/3 e. Remove two capscrews (1), connecting rod (3), and bearing cap (2). f. If damaged or worn, remove bearing halves (4). g. Carefully scrape any build up of carbon from top of cylinder bore. h. Rotate crankshaft until piston is at TDC. i. Install (hand-tighten) a capscrew (1) into nearest connecting rod bearing cap bolt hole. j. Using a suitable lever against crankcase and end of capscrew, press down on end of lever until piston rings are clear of cylinder bore. k. Lift out piston (5) and connecting rod (3) and tag with corresponding cylinder number. I. Install bearing cap (2) onto connecting rod (3). 3-30.2.  Inspect and Measure. a. Thoroughly clean cylinder barrel.  Check for scoring and wear. b. Clean piston (5, FIGURE 3-36) by removing all traces of carbon from both upper and underside of crown and ring grooves. c. Check  for  correct  gap  clearance.    Refer  to  TABLE  3-6,  with  piston  rings  (6)  in  an  unworn  section  of  cylinder barrel. d. Clean connecting rod (3). e. Check bushing (9) for wear.  Replace if worn. f. If big end has been disassembled because of metal failure, oil passages in crankshaft must also be examined for obstruction and fragments of metal. NOTE The maximum advisable piston to cylinder clearance given is the clearance between the bottom of the  piston  skirt,  across  the  faces,  and  the  cylinder  bore  measured  in  the  region  of  travel  of  the piston  skirt.    The  clearance  is  not  to  be  measured  at  the  top  of  the  bore.  When  cylinders  are rebored, the lower skirt should be etched or painted with the amount of the oversize. NOTE The  ring  gaps  given  in  TABLE  3-6  are  those  to  be  anticipated  when  checking  rings  in  an  unworn part of the bore.  For every 0.01 mm (0.0004 in.) by which the actual bore size exceeds the initial dimension,  the  ring  gap  will  increase  by  approximately  0.03  mm  (0.0012  in.)  The  firing  ring  side clearance is measured with a new ring flush with the top piston land. NOTE Oversize  pistons  and  piston  rings,  and  undersize  big  end  and  main  bearing  shells  are  available. Nonstandard  sizes  are  marked,  by  the  amount  they  are  under  or  oversize,  as  a  suffix  to  the  part numbers which can be found in the following locations: Piston Rings - stamped on the face of the ring. Pistons stamped on the top surface. Bearings stamped on the steel outside surface of the bearing. g. Using appropriate measuring devices, check components listed in TABLE 3-6 for wear.  Replace components that exceed maximum clearance. 3-62


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