TM-9-2320-260-34-1
TRUCK, 5-TON, 6X6, M809 SERIES (DIESEL)
TECHNICAL MANUAL; DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE; VOLUME 1 OF 2
JULY 1994
TM-9-2320-260-34-1 - Page 232 of 657
TM 9-2320-260-34-1
3-55. PISTON AND CONNECTING ROD INSTALLATION
THIS TASK COVERS:
a. Assembly
c. Connecting Rod Side Clearance
b. Installation
INITIAL SETUP
APPLICABLE MODELS
MATERIALS/PARTS
All
Piston pin bushing (Appendix D, Item
9)
Piston ring set (Appendix D, Item 486)
TOOLS
Lubricating oil (Appendix C, Item 21)
General mechanic’s tool kit
(Appendix B, Item 1)
PERSONNEL REQUIRED
Piston ring compressor (Appendix B, Item 15)
Two
Torque wrench, 3/8-in. dr.
(Appendix B, Item 4)
REFERENCES (TM)
Arbor press (Appendix B, Item 7)
TM 9-2320 -260-34P-1
Feeler gage (Appendix B, Item 58)
a. Assembly
1. Install alinement pin (7) in connecting rod (6).
2. Using arbor press, install new piston pin bushing (5) in connecting rod (6).
3. Using arbor press, install piston pin (4) in piston (2) and connecting rod (6).
4. Install two retaining rings (3) in piston (2).
5. Install new piston rings (1) on piston (2) in original order.
b. Installation
CAUTION
• Ensure cylinder liner is clean before installing connecting rod
and piston.
• Ensure connecting rod and cap are matched set.
NOTE
• Refer to para. 3-47 for cleaning and inspection of piston and
connecting rod.
• Connecting rods and pistons are installed the same. This
procedure covers installation of one piston and connecting rod,
• Coat parts with clean engine oil before installation.
1. Install bearing shell (9) on connecting rod (6). Ensure tang on bearing shell (9) engages notch on
connecting rod (6).
CAUTION
Assistant must guide connecting rod through cylinder from oil pan
side of cylinder block to avoid damage to cylinder liner or crank-
shaft.
NOTE
Ensure numbered side of connecting rod faces camshaft.
2. Install piston ring compressor on piston (2) and insert connecting rod (6) in cylinder (10) until piston
ring compressor is seated firmly against cylinder block (8).
3-180
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