0386235 JOHNSON GEARCASE ASSY.,Long

Illustration 1 g00587672
Use the following references: Piston Pins And Retaining Rings, SEBF8051, Pistons, SEBF8049 and Cylinder Liners, SEBF8068. These references are located in Guidelines For Reusable Parts.Note: Connecting rods and caps should be marked by etching. Etch the number of the cylinder that corresponds with the connecting rod and cap. These numbers should be on the side of the connecting rod with the bearing tab slots. (1) Piston ringUse 5P-3519 Piston Ring Groove Gauge in order to check the top ring groove. Refer to Pistons And Cylinder Liners, SEBF8001 for instructions on the use of the gauge.Install the top ring with the "UP-1" mark toward the top of the piston.Width of groove in piston for piston ring ... 3.864 0.010 mm (0.1521 0.0004 inch)Thickness of new piston ring ... 3.809 + 0.000 - 0.038 mm (0.1500 + 0.0000 - 0.0015 inch)Clearance between groove and new piston ring ... 0.045 to 0.103 mm (0.0018 to 0.0041 inch)Maximum permissible worn clearance ... 0.15 mm (0.006 inch)When a new piston ring is installed in a cylinder liner that has a bore size of 137.16 mm (5.400 inch), the clearance between the ends of the piston ring is the following value. ... 1.000 0.190 mm (0.0394 0.0075 inch)There is an 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 size by the following value. ... 0.08 mm (0.003 inch) (2) Intermediate ringInstall the intermediate ring with the "UP-2" mark toward the top of the piston.Width of groove in piston for new piston ring ... 3.060 0.010 mm (0.1205 0.0004 inch)Thickness of new piston ring ... 2.970 to 3.000 mm (0.1169 to 0.1181 inch)Clearance between groove and new piston ring ... 0.050 to 0.100 mm (0.0020 to 0.0039 inch)Maximum permissible worn clearance ... 0.15 mm (0.006 inch)When a new piston ring is installed in a cylinder liner with a bore size of 137.16 mm (5.400 inch), the clearance between the ends of the piston ring is the following value. ... 0.46 0.10 mm (0.0181 0.004 inch)There is an 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 size by the following value. ... 0.08 mm (0.003 inch) (3) Oil control ringInstall the oil control ring. The gap in the spring must be 180 degrees away from the gap in the ring.Width of groove in piston for new piston ring ... 4.030 0.010 mm (0.1587 0.0004 inch)Thickness of new piston ring ... 3.975 0.015 mm (0.1565 0.0006 inch)Clearance between groove and new piston ring ... 0.030 to 0.080 mm (0.0012 to 0.0031 inch)Maximum permissible worn clearance ... 0.15 mm (0.006 inch)When a new piston ring is installed in a cylinder liner with a bore size of 137.16 mm (5.400 inch), the clearance between the ends of the piston ring is the following value. ... 1.200 0.175 mm (0.0472 0.0069 inch)There is an 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 size by the following value. ... 0.08 mm (0.003 inch) (4) Gallery for cooling piston (5) Bore in piston for pin ... 50.815 0.008 mm (2.0006 0.0003