Piston ring breakage may occur If rings are opened more than necessary when removing. Never
stretch piston rings more than necessary.
i. the piston ring remover tool to remove piston rings Discard piston rings.
Prior to Inspecting/evaluating the piston and connecting rod assembly, evaluate the cylinder.
Check that the cylinder ID Is no greater than 2.684 Inches (68.16 mm). If the cylinder sleeve Is
greater than this wear limit, follow the procedures to replace the crankcase.
a. Clean piston (5) and piston pin (7)
b. Remove carbon from piston and piston components.
c. Carefully clean the piston ring groove after the piston rings have been removed
d. Inspect piston, piston skirt, piston grooves, and piston pin for excessive wear, discoloration, and damage Replace
Before reading any measurements, all carbon buildup must be removed. Carbon buildup will
cause unreliable measurements.
e. Check that the OD of piston is greater than 2 665 inches (67.68 mm) Measure piston OD 90 degrees from the
piston pin hole and about 0 50 inch (12 mm) from the bottom of piston Replace piston if worn beyond the wear
f. Check that the ID of the piston pin hole Is less than 0.751 inch (19 07 mm) Replace piston it ID exceeds wear limit
g. Check that the OD of the piston pin is greater than 0.745 inch (18 92 mm) Replace piston pin if OD Is worn
beyond the wear limit
h. Clean connecting rod components with diesel fuel
i. Inspect all connecting rod components for bending, warping, cracking, excessive wear, or any other damage
Replace any components damaged or worn
j. Check that piston pin hole ID (small end hole) of connecting rod Is less than 0 752 inch (19 1 mm) Replace
connecting rod it piston pin hole diameter exceeds wear limit.
k. Check that crank pin hole ID (large end hole) of connecting rod is less than 1 184 Inches (30 08 mm) Replace
connecting rod if crank pin hole diameter exceeds wear limit