0389968 JOHNSON GEAR AND PINION ASSY.

Illustration 1 g00845975 (1) The chamber that is on the top of the piston must face the right side of the engine. (2) The Shibaura name that is on the inside of the piston must align with the stamped number on the connecting rod. Piston and Piston Rings
Illustration 2 g00845969Use a feeler gauge to measure the clearance between the piston ring groove and the piston ring. If the clearance is greater than the service limit, use a new piston ring and check the clearance.If the clearance is within the service limit, renew the piston rings. If the clearance is outside of the service limit, renew the piston. (1) Top piston ring Shape of top ring (A) Naturally aspirated ... Barrel faceTurbocharged ... KeystoneClearance between piston ring groove and top piston ring ... 0.07 to 0.11 mm (0.0028 to 0.0043 inch)Service limit for clearance of top piston ring ... 0.25 mm (0.0098 inch)Gap of top piston ring ... 0.20 to 0.35 mm (0.0079 to 0.0138 inch)Service limit for gap of top piston ring ... 1.0 mm (0.039 inch)Note: It is difficult to measure the wear of the top piston ring. When either the intermediate ring or the oil control ring is outside the service limit, renew all of the rings.Note: Install the word "Top" toward the top of the piston. New top piston rings have a red identification mark which must be on the left of the ring gap when the top piston ring is installed on an upright piston.Note: New top piston rings have a yellow identification mark which must be on the left of the ring gap when the top piston ring is installed on an upright piston.Note: The top surface of the piston ring should be equally distant from the top face of the cylinder block at all points before the piston ring end gap is measured with a feeler gauge. (2) Intermediate ring Shape of intermediate ring (B) ... TaperClearance between piston ring groove and intermediate ring ... 0.04 to 0.08 mm (0.0016 to 0.0032 inch)Service limit for clearance of intermediate ring ... 0.25 mm (0.0098 inch)Gap of intermediate ring ... 0.20 to 0.40 mm (0.0079 to 0.0158 inch)Service limit for gap of intermediate ring ... 1.0 mm (0.039 inch)Note: Install the word "Top" toward the top of the piston. New intermediate rings have a green identification mark which must be on the left of the ring gap when the intermediate ring is installed on an upright piston.Note: The top surface of the piston ring should be equally distant from the top face of the cylinder block at all points before the piston ring end gap is measured with a feeler gauge. (3) Oil control ring Clearance between piston ring groove and oil control ring ... 0.02 to 0.06 mm (0.0008 to 0.0024 inch)Service limit for clearance of oil control ring ... 0.15 mm (0.0059 inch)Gap of oil control ring ... 0.20 to 0.40 mm (0.0079 to 0.0158 inch)Service limit for gap of oil control ring ... 1.0 mm (0.039 inch)The oil control ring has two components. The two components of the oil control ring are installed in the following order.
Spring (D)
Oil control ring (C) Note: A latch pin is used in order to hold both ends of the spring of the oil control ring in position. The ends of the spring of the oil control ring must be 180 degrees opposite the end gap of the oil control ring.Note: The top surface of the piston ring should be equally distant from the top face of the cylinder block at all points before the piston ring end gap is measured with a feeler gauge. (4) Piston Diameter of the piston skirt ... 83.948 to 83.963 mm (3.3050 to 3.3056 inch)Service limit ... 83.7 mm (3.295 inch)Clearance of the piston skirt to the cylinder wall ... 0.0380 to 0.0720 mm (0.00150 to 0.00283 inch)Service limit ... 0.25 mm (0.010 inch)Diameter of the piston pin ... 27.996 to 28.000 mm (1.1022 to 1.1024 inch)Service limit ... 27.98 mm (1.1016 inch)Clearance between the hole for the piston pin and the piston pin ... −0.001 to +0.007 mm (−0.0004 to +0.0003 inch)Service limit ... 0.02 mm (0.0008 inch)Refer to Specifications, "Cylinder Head" for the piston height for a given gasket thickness.