0389169 JOHNSON MOTOR COVER ASSY,, 100 HP

Illustration 1 g00891033
Six cylinder engine is shown. (1) Cylinder liner (2) Plug with baffle plates (if equipped) Orientation of baffle plates to the vertical plane ... +/- 5 degrees Depth of plug from face of cylinder block ... 3 mm (0.12 inch) (3) Cylinder block Diameter of the bore for the cylinder liner ... 104.20 to 104.23 mm (4.103 to 4.104 inch) Depth of the recess for the cylinder liner flange ... 3.81 to 3.91 mm (0.150 to 0.154 inch) Diameter of the recess for the cylinder liner flange ... 107.82 to 107.95 mm (4.245 to 4.250 inch) (4) Tighten the bolts that fasten the housing for the crankshaft rear seal to the cylinder block to the following torque. ... 22 N m (16 lb ft) (5) Tighten the bolts that fasten the housing for the crankshaft rear seal to the bridge to the following torque. M6 ... 13 N m (10 lb ft) M8 ... 22 N m (16 lb ft) (6) Bridge boltUse the following procedure in order to install the bridge bolts.
Use a straight edge in order to ensure that the bridge is aligned with the front face of the cylinder block.
Evenly tighten the bridge bolts to a torque of 16 N m (12 lb ft).
When the bridge is installed on the cylinder block, apply a thin bead of 8T-9013 Silicone Sealant into the groove at each end of the bridge. (7) Main bearing cap boltsUse the following procedure in order to install the main bearing cap bolts.
Apply clean engine oil to the threads of the main bearing cap bolts.
Put the main bearing caps in the correct position that is indicated by a number on the top of the main bearing cap. Install the main bearing caps with the locating tabs in correct alignment with the recess in the cylinder block.
Evenly tighten the main bearing cap bolts to a torque of 265 N m (195 lb ft). (8) Bore in the cylinder block for the main bearings ... 80.416 to 80.442 mm (3.1660 to 3.1670 inch) (9) Camshaft bearingFour cylinder engine Inside diameter of the camshaft bearing for the number 1 camshaft journal ... 50.79 to 50.85 mm (2.000 to 2.002 inch) Bore diameter in the cylinder block for the number 1 camshaft bearing ... 55.56 to 55.59 mm (2.187 to 2.189 inch) Bore diameter in the cylinder block for the number 2 camshaft journal ... 50.55 to 50.60 mm (1.990 to 1.992 inch) Bore diameter in the cylinder block for the number 3 camshaft journal ... 50.04 to 50.09 mm (1.970 to 1.972 inch)Six cylinder engine Inside diameter of the camshaft bearing for the number 1 camshaft journal ... 50.79 to 50.85 mm (2.000 to 2.002 inch) Bore diameter in the cylinder block for the number 1 camshaft bearing ... 55.56 to 55.59 mm (2.187 to 2.189 inch) Bore diameter in the cylinder block for the number 2 camshaft journal ... 50.55 to 50.60 mm (1.990 to 1.992 inch) Bore diameter in the cylinder block for the number 3 camshaft journal ... 50.29 to 50.34 mm (1.980 to 1.982 inch) Bore diameter in the cylinder block for the number 4 camshaft journal ... 50.04 to 50.09 mm (1.970 to 1.972 inch)Total height of the cylinder block between the top and the bottom faces. ... 441.12 to 441.33 mm (17.367 to 17.375 inch)