0396394 EVINRUDE INTAKE MANIFOLD ASSEMBLY

Illustration 1 g00595557Note: The word "FRONT" is stamped on the crown of one piece pistons (1). Install the piston with the word "FRONT" toward the front of the engine. The front of the engine is opposite the flywheel end. The part number on the connecting rod should be facing the rear of the engine. The rear of the engine is the flywheel end. Lubricate the entire piston prior to assembly into the cylinder block. Use clean engine oil.
Illustration 2 g00595622
Typical example
Top Ring
(2) Top ring The top ring is marked with "UP-1".Install the top ring with the side marked "UP-1" toward the top of the piston. The colored stripe faces to the right of the ring end gap.The ends of the piston ring have a clearance when the piston ring is installed in a cylinder with a specific bore size.3114 and 3116 Engines
Cylinder bore size ... 105.025 mm (4.1348 inch)Clearance ... 0.615 0.125 mm (0.0242 0.0049 inch)Increase in clearance between ends of piston ring for each 0.03 mm (0.001 inch) increase in cylinder bore size ... 0.09 mm (0.0035 inch)3126 Engines
Cylinder bore size ... 110.025 mm (4.3317 inch)Clearance ... 0.56 0.10 mm (0.022 0.004 inch)Increase in clearance between ends of piston ring for each 0.01 mm (0.0004 inch) increase in cylinder bore size ... 0.031 mm (0.0012 inch)Intermediate Ring
(3) Intermediate ring The intermediate ring is marked with "UP-2".Install the piston ring with the side marked "UP-2" toward the top of the piston. The colored stripe faces to the right of the ring end gap.The ends of the piston ring have a clearance when the piston ring is installed in a cylinder with a specific bore size.3114 and 3116 Engines
Cylinder bore size ... 105.025 mm (4.1348 inch)Clearance ... 0.918 0.125 mm (0.0361 0.0049 inch)Increase in clearance between ends of piston ring for each 0.03 mm (0.001 inch) increase in cylinder bore size ... 0.09 mm (0.0035 inch)3126 Engines
Cylinder bore size ... 110.025 mm (4.3317 inch)Clearance ... 0.904 0.125 mm (0.0356 0.0049 inch)Increase in clearance between ends of piston ring for each 0.01 mm (0.0004 inch) increase in cylinder bore size ... 0.031 mm (0.0012 inch)Oil Control Ring
(4) Oil control ring The oil control piston ring has a spring that is installed with the ring. The gap in the spring should be a distance of 180 degrees from the ring end gap when the oil control piston ring is assembled. The colored portion of the spring must be visible at the ring end gap.Width of oil control ring groove in new piston ... 4.041 0.013 mm (0.1591 0.0005 inch)Thickness of new oil control ring ... 3.982 0.008 mm (0.1568 0.0003 inch)Clearance between a new piston ring groove and a new piston ring ... 0.038 to 0.080 mm (0.0015 to 0.0031 inch)The ends of the piston ring have a clearance when the piston ring is installed in a cylinder with a specific bore size.3114 and 3116 Engines
Cylinder bore size ... 105.025 mm (4.1348 inch)Clearance ... 0.54 0.15 mm (0.021 0.006 inch)Increase in clearance between ends of piston ring for each 0.03 mm (0.001 inch) increase in cylinder bore size ... 0.09 mm (0.0035 inch)3126 Engines
Cylinder bore size ... 110.025 mm (4.3317 inch)Clearance ... 0.379 0.100 mm (0.0149 0.0039 inch)Increase in clearance between ends of piston ring for each 0.01 mm (0.0004 inch) increase in cylinder bore size ... 0.031 mm (0.0012 inch)After all the piston rings are installed, check and rotate the rings. The rotation is necessary to separate the end gaps in order to prevent alignment. The separation is the following amount. ... 120 degreesPiston Pin
(5) Piston pin Piston pin bore diameter ... 40.020 0.008 mm (1.5756 0.0003 inch)Piston pin diameter ... 40.000 0.005 mm (1.5748 0.0002 inch)Thoroughly lubricate the piston pin with clean engine oil prior to assembly.Two-Piece Articulated Piston
Illustration 3 g00293184
Illustration 4 g00293185 (1) Crown assembly (2) Connecting rod Note: Assemble the connecting rod and piston group. Install the connecting rod and piston group in the cylinder block. The part number on the connecting rod should be facing the rear of the engine. The rear of the engine is the flywheel end of the engine. Lubricate the entire piston prior to assembly into the cylinder block. Use clean engine oil. Top Ring
(3) The top ring has the mark "UP-1". Install the top ring with the side marked "UP-1" toward the top of the piston. The colored stripe faces to the right of the ring end gap.The ends of the piston ring have a clearance when the piston ring is installed in a cylinder with a specific bore size.3114 and 3116 Engines
Cylinder bore size ... 105.025 mm (4.1348 inch) 105-1746 Piston Ring 107-7548 Piston RingNote: These rings have a plasma face coating.Clearance ... 0.660 0.190 mm (0.0260 0.0075 inch) 107-7787 Piston Ring Note: These rings have a chrome finish.Clearance ... 0.615 0.010 mm (0.0242 0.0004 inch)Increase in clearance between ends of piston ring for each 0.03 mm (0.001 inch) increase in cylinder bore size ... 0.09 mm (0.0035 inch)3126 Engines
Cylinder bore size ... 110.025 mm (4.3317 inch) 119-2990 Piston Ring Note: These rings have a plasma fac