0436220 JOHNSON ENGINE COVER ASSY.

Illustration 1 g01637696
Note: Etch the cylinder number on the connecting rod and the cap. Mark the numbers on the same side of the connecting rod as the bearing retainer notch. Install the rod in the piston so that the etched cylinder number on the rod is on the same side as the "V" mark on the piston.Note: Thoroughly lubricate the entire piston in zone (A) with clean engine oil prior to assembly into the cylinder block.Note: Install the piston so that the "V" mark on the top of the piston is on the same side as the "V" mark on top of the cylinder block.Top Piston Ring (1)
Install the top piston ring with the side marked "UP-1" toward the top of the piston. The red stripe faces to the right of the end gaps of the piston ring.Clearance between the ends of the piston ring in a cylinder liner bore of 120.65 mm (4.750 inch) ... 0.62 0.19 mm (0.024 0.007 inch)Increase in the clearance between the ends of the piston ring for each 0.03 mm (0.001 inch) increase in the cylinder liner bore ... 0.08 mm (0.003 inch)Thickness of new top piston ring ... 3.135 0.015 mm (0.1234 0.0006 inch)Width of groove in piston for new piston ring ... 3.230 0.010 mm (0.1272 0.0004 inch)Clearance between groove and new piston ring ... 0.070 to 0.120 mm (0.0028 to 0.0047 inch)Maximum permissible worn clearance ... 0.15 mm (0.006 inch)Intermediate Piston Ring (2)
Install the intermediate piston ring with the side marked "UP-2" toward the top of the piston. The green stripe faces to the right of the end gaps of the piston ring.Clearance between the ends of the piston ring in a cylinder liner bore of 120.65 mm (4.750 inch) ... 0.62 0.19 mm (0.024 0.007 inch)Increase in the clearance between the ends of the piston ring for each 0.03 mm (0.001 inch) increase in the cylinder liner bore ... 0.08 mm (0.003 inch)Thickness of new intermediate piston ring ... 2.360 0.015 mm (0.0929 0.0006 inch)Width of groove in piston for new piston ... 2.455 0.010 mm (0.0967 0.0004 inch)Clearance between groove and new piston ring ... 0.070 to 0.120 mm (0.0028 to 0.0047 inch)Maximum permissible worn clearance ... 0.15 mm (0.006 inch)Oil Control Piston Ring (3)
Clearance between the groove and the new piston ring in a cylinder liner bore of 120.65 mm (4.7500 inch) ... 0.57 0.19 mm (0.022 0.007 inch)Increase in the clearance between the ends of the piston ring for each 0.03 mm (0.001 inch) increase in the cylinder liner bore ... 0.08 mm (0.003 inch)Thickness of new oil control piston ring ... 3.983 0.007 mm (0.1568 0.0003 inch)Width of groove in piston for new piston ring ... 4.030 0.010 mm (0.1587 0.0004 inch)Clearance between groove and new piston ring ... 0.070 to 0.120 mm (0.0028 to 0.0047 inch)Maximum permissible worn clearance ... 0.15 mm (0.006 inch)Note: After the piston rings have been installed, rotate the piston rings so that the end gaps are 120 degrees from each other.Piston Pin (4)
Note: Thoroughly lubricate the piston pin with clean engine oil before the piston pin is inserted into the piston body assembly and the rod assembly.Outer diameter of the new piston pin ... 38.108 0.005 mm (1.5003 0.0002 inch)Inner diameter of the new piston pin ... 20.50 0.51 mm (0.807 0.020 inch)Length of the new piston pin ... 94.74 0.13 mm (3.730 0.005 inch)Bore in the new piston body assembly for the piston pin ... 38.128 0.005 mm (1.5011 0.0002 inch)