0386678 JOHNSON CAP ASSEMBLY, Common end

Illustration 1 g00284985
Right side view (1) DowelApply 7M-7456 Compound to the dowel before installation. The dowel extends above the top surface of the cylinder block by the following distance. ... 18.5 0.5 mm (0.73 0.02 inch) (2) Spacer plate Thickness of the spacer plate ... 8.585 0.025 mm (0.3380 0.0010 inch) Thickness of the gasket that is placed between the spacer plate and the cylinder block ... 0.238 0.032 mm (0.0094 0.0013 inch) Cylinder liner projection above the spacer plate ... 0.025 to 0.152 mm (0.0010 to 0.0060 inch) (3) Dowel The dowel extends above the top surface of the cylinder block by the following distance. ... 16.0 0.5 mm (0.63 0.02 inch) (4) DowelApply 7M-7456 Compound to the dowel before installation. The dowel extends above the top surface of the cylinder block by the following distance. ... 20.0 0.5 mm (0.79 0.02 inch) (5) Plug Tighten the plug to the following torque. ... 70 10 N m (52 7 lb ft) (6) Dowel The dowels extend past the end of the cylinder block by the following distance. ... 19.1 0.5 mm (0.75 0.02 inch)
Illustration 2 g00284986
View A-A
Illustration 3 g00562849
View B-B (7) Installation depth of the plug ... 2.0 2.0 mm (0.08 0.08 inch)
Illustration 4 g00284988
Front view (8) Dimension from the centerline of the crankshaft bearing bore to the top of the cylinder block New ... 425.45 0.15 mm (16.750 0.006 inch) Minimum ... 425.02 mm (16.733 inch)Note: The total flatness of the top contact surface of the cylinder block must be within 0.10 mm (0.004 inch). The flatness must also be within 0.05 mm (0.002 inch) for any 177.5 mm (6.99 inch) section of the surface. (9) Bore in the cylinder block for the main bearings (10) Main bearing cap Main bearing cap width ... 215.900 0.025 mm (8.5000 0.0010 inch) Width of the cylinder block for the main bearing cap ... 215.900 0.013 mm (8.5000 0.0005 inch) (11) Main bearing cap bolts
Illustration 5 g00562863
Torque-turn tightening method for main bearing cap boltsUse the following procedure in order to tighten the main bearing cap bolts:
Apply clean engine oil to the threads of the bolts.
Tighten the bolts first on the bearing tab side (1) of the cap.Torque for bolts ... 260 14 N m (190 10 lb ft)
Tighten the bolts on the opposite side (2) .Torque for bolts ... 260 14 N m (190 10 lb ft)
Put a mark on each bolt and each cap.
Tighten the bolts on the opposite side (3) from the mark to angle (A) .Angle (A) ... 120 5 degrees (2 flats)
Tighten the bolts on the bearing tab side (4) of the cap from the mark to the following value.Angle (A) ... 120 5 degrees (2 flats) (12) New dimension from the centerline of the crankshaft bearing bore to the bottom of the cylinder block pan rails ... 165.10 0.10 mm (6.500 0.004 inch)
Illustration 6 g00285129
Right side view (13) Pipe plugApply 5P-3413 Pipe Sealant on the threads of the pipe plugs before installation in the cylinder block. (14) Piston cooling jetTo prevent damage to the piston cooling jets during service, the piston cooling jets must be removed. Tighten the bolts that hold the piston cooling jets to the following torque. ... 40 8 N m (30 6 lb ft) Minimum permissible clearance between the piston, the piston cooling jet, and the crankshaft ... 0.63 mm (0.025 inch)