0439015 EVINRUDE PISTON & RING ASSY., Port, 0.020 in. O.S.

Illustration 1 g00636808
Naturally Aspirated Engines
(1) Inside diameter of rod for bearing ... 38.89 to 38.92 mm (1.531 to 1.532 inch) (2) Outside diameter of bearing for piston pin ... 38.94 to 39.03 mm (1.535 to 1.536 inch)Inside diameter of bearing for piston pin after reaming ... 34.940 to 34.960 mm (1.3758 to 1.3765 inch)Clearance between small end bearing and piston pin ... 0.020 to 0.043 mm (0.0008 to 0.0017 inch) (3) Distance between center of piston pin and center of crankshaft bearing ... 219.05 to 219.10 mm (8.624 to 8.626 inch) (4) Bearings are available for remachined journals of the crankshaft which have the following undersize dimensions:0.25 mm (0.010 inch)0.51 mm (0.020 inch)0.76 mm (0.030 inch)Shell thickness ... 1.835 to 1.842 mm (0.0723 to 0.0726 inch)Width of connecting rod bearing ... 31.62 to 31.88 mm (1.245 to 1.255 inch)Bearing clearance ... 0.035 to 0.081 mm (0.0014 to 0.0032 inch) (5) Inside diameter of rod for bearing ... 67.210 to 67.220 mm (2.6460 to 2.6465 inch) (6) Connecting rod cap with nuts and boltsTighten the nuts for the connecting rod to the following torque: ... 125 N m (92 lb ft)Connecting rod cap with bolts onlyTighten the bolts for the connecting rod to the following torque: ... 155 N m (114 lb ft)Turbocharged Engines
(1) Inside diameter of rod for bearing ... 42.07 to 42.09 mm (1.656 to 1.657 inch) (2) Outside diameter of bearing for piston pin ... 42.160 to 42.190 mm (1.6600 to 1.6613 inch)Inside diameter of bearing for piston pin after reaming ... 38.120 to 38.140 mm (1.5008 to 1.5015 inch)Clearance between small end bearing and piston pin ... 0.020 to 0.043 mm (0.0008 to 0.0017 inch) (3) Distance between center of piston pin and center of crankshaft bearing ... 219.05 to 219.10 mm (8.624 to 8.626 inch) (4) Bearings are available for remachined journals of the crankshaft which have the following undersize dimensions:0.25 mm (0.010 inch)0.51 mm (0.020 inch)0.76 mm (0.030 inch)Shell thickness ... 1.835 to 1.844 mm (0.0723 to 0.0726 inch)Width of connecting rod bearing ... 31.55 to 31.88 mm (1.240 to 1.255 inch)Bearing clearance ... 0.030 to 0.081 mm (0.0012 to 0.0032 inch) (5) Inside diameter of rod for bearing ... 67.210 to 67.220 mm (2.6460 to 2.6465 inch) (6) Connecting rod cap with nuts and boltsTighten the nuts for the connecting rod to the following torque: ... 125 N m (92 lb ft)Connecting rod cap with bolts onlyTighten the bolts for the connecting rod to the following torque: ... 155 N m (114 lb ft)Note: If piston cooling jets are installed, the piston and the connecting rod assembly must be turned when the piston and rod assembly are installed. Turning the piston and connecting rod assembly will prevent the connecting rod from hitting and damaging the piston cooling jet. When the connecting rod has passed the piston cooling jet, turn the connecting rod until the arrow or "Front" mark on the top of the piston is toward the front of the engine.The piston height is controlled by the length of the connecting rod. Connecting rods are supplied in six grades of length. The different grades of length are manufactured by machining the hole in the piston pin bearing in an off-center position. The different grades of length are created by the following method:
Machining the center of the hole in the piston pin
Machining the center of the hole in the bearing
If the connecting rod is replaced, ensure that the same grade of length as the original connecting rod is used.However, if the crankshaft or the cylinder block is replaced, the required grade of length of the connecting rods may change.A correct grade of length of a connecting rod can be ordered for replacement. The connecting rod includes the piston pin bearing. The piston pin bearing is machined in order to create the correct grade of length. The piston pin is installed in the connecting rod at the factory. Table 1 provides the specifications for the grade of length.Note: The length of the connecting rod is determined by the following method: The bearing for the crankshaft journal must be removed and the piston pin must be installed. The original grade of length of the connecting rod is determined when the original piston pin is installed.
Table 1
Length Grades for the Connecting Rod    
Grade Letter     Color Code     Length    
F     Red    
165.728 to 165.761 mm (6.5247 to 6.5260 inch)    
G     Orange    
165.682 to 165.715 mm (6.5229 to 6.5242 inch)    
H     White    
165.637 to 165.670 mm (6.5211 to 6.5224 inch)    
J     Green    
165.591 to 165.624 mm (6.5193 to 6.5206 inch)    
K     Purple    
165.545 to 165.578 mm (6.5175 to 6.5188 inch)    
L     Blue    
165.499 to 165.532 mm (6.5157 to 6.5170 inch)    
S (1)     -    
165.571 to 165.635 mm (6.5185 to 6.5210 inch)    
( 1 ) A new piston and a new piston pin bearing have been installed.