0507122 JOHNSON Service Manual

Illustration 1 g06344752
Table 1
Item Qty Part Specification Description
1 1 223-9159 Top Piston Ring Install the top piston ring with the side marked "UP-1" toward the top of the piston. The colored stripe faces to the right of the piston ring end gap.
Thickness of new top piston ring is 3.845 mm (0.1514 inch).
Clearance between the ends of the piston ring in a cylinder liner bore of 144.975 mm (5.7077 inch) is 0.40 0.10 mm (0.016 0.004 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 is 0.08 mm (0.003 inch).
2 1 238-2707 Piston Ring Install the intermediate piston ring with the side marked "UP-2" toward the top of the piston. The colored stripe faces to the right of the piston ring end gap.
Thickness of new intermediate piston ring is 2.94 mm (0.116 inch).
Clearance between the ends of the piston ring in a cylinder liner bore of 144.975 mm (5.7077 inch) is 0.600 0.125 mm (0.0236 0.0049 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 is 0.08 mm (0.003 inch).
3 1 246-5659 Piston Ring The spring ends of the oil control ring should be assembled 180 degrees from the ring end gap. The colored faces to the right or left of the piston ring end gap.
Width of groove in new piston for oil control piston ring is 3.020 0.010 mm (0.1189 0.0004 inch).
Thickness of new oil control piston ring is 2.980 0.010 mm (0.1173 0.0004 inch).
Clearance between the ends of the piston ring in a cylinder liner bore of 144.975 mm (5.7077 inch) is 0.55 0.15 mm (0.022 0.006 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 is 0.08 mm (0.003 inch).
4 1 524-5565 Piston Pin Thoroughly lubricate the piston pin with clean engine oil before the piston is inserted into the piston body and the connecting rod.
Diameter of the bore in the finished bearing that is installed into the piston skirt for the piston pin is 60.125 0.005 mm (2.3671 0.00020 inch).
Diameter of the new piston pin is 59.975 0.005 mm (2.3612 0.0002 inch).
Length of the piston pin is 89.80 0.15 mm (3.535 0.006 inch).
Install the retainer ring (5) with the gap at the bottom of the piston. Refer to Illustration 1.
6 2 213-3217 Bolt Use the following procedure to tighten the rod bolts:
1. Before assembly, lubricate the rod bolts with engine oil.
2. Tighten the bolt to 70 4 N m (52 3 lb ft).
3. Again, tighten the bolt to 70 4 N m (52 3 lb ft) to an addition angle of 60 degrees 5 degrees.
7 2 213-3217 Bolt Use the following procedure to tighten the rod bolts:
1. Before assembly, lubricate the rod bolts with engine oil.
2. Tighten the bolt to 70 4 N m (52 3 lb ft) to an additional angle of 60 degrees 5 degrees.
3. Again, tighten the bolt to 70 4 N m (52 3 lb ft).
8 1 151-5925 Bolt Torque to 40 8 N m (30 6 lb ft)
Thoroughly lubricate the entire piston in zone (A) with clean engine oil prior to assembly into the cylinder block
After the piston rings have been installed, rotate the piston rings so that the end gaps are placed at 120 degrees distance from each other.