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PISTON AND CONNECTING ROD MAINTENANCE
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TM-5-4210-229-14P Truck Firefiighting 1000 GPM Multipurpose Model 2500L Manual
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INSPECTION - TM-5-4210-229-14P_423
TM5-4210-229-14&P 6-12.  PISTON AND CONNECTING ROD MAINTENANCE (Continued). CAUTION It is advisable to wrap an oil-soaked cloth around the crankshaft connecting rod bearing journals to keep them as clean as possible.  Wrap the piston and connecting rod assemblies in clean cloth also to protect them until installation. b.  Remove the connecting rod bolts from the rod caps and remove the caps and bearing inserts from the rod ends.  Keep in order and observe markings to prevent mismatching. c.  Push the connecting rod and piston to the top of the cylinder and remove them from the top of the crankcase with extreme care. d.  Crank the engine by hand and remove all of the remaining pistons as outlined.  Be sure to re- place each bearing cap on its respective con- necting rod after removal of the piston from the engine. e.  Cylinder sleeve removal. (1) After piston and rod removal use the uni- versal wet sleeve puller and remove cylin- der sleeves. (2) Position the puller in the sleeve.  Hold the jaws of the puller and turn the screw, which spreads the jaws to grip the edge of the cylinder sleeve.  Tighten the locking bar against the top of the sleeve. (3) Turn the bearing-mounted forcing nut to break the cylinder sleeve loose from the crankcase. CAUTION If more than one sleeve is to be removed and they are to be used again, it is important that the sleeves be marked with the cylinder num- ber they were removed from. (4) Remove the sleeve; if necessary thread a slide hammer into the forcing screw to aid in removal. f.  Connecting rods, pistons and rings disassembly. (1) Remove the piston rings (1, 2, and 3) with a piston ring expander.  Remove the top com- pression ring first then the remaining rings in order. (2) Remove the piston pin retainers (4) from each piston. CAUTION Do not apply excessive force to the piston pin. It is recommended that the piston be heated in water to 160°-180° F (71°-82° C) if the pin cannot be removed by hand when cold. (3) Remove the piston pin (5) by hand. (4) After the pin is removed, separate the pis- ton (6) from the connecting rod (7).  Tag or mark the piston and parts with the number of the bore from which they were taken, so they may be reinstalled in their respective cylinders once inspected and/or repaired. 6-29

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