9101F4-0835 Tohatsu BOLT

Illustration 1 g01412733
Typical example (4) Gallery for cooling pistonNote: Assemble the body assembly to the rod so that the colored markings on the pin boss of the body assembly are on the same pin boss.Refer to Reuse And Salvage Guidelines, SEBF8049, "Visual Inspection of the Piston", Reuse And Salvage Guidelines, SEBF8051, "Inspection and Measuring Procedures for Piston Pins", and Guideline For Reusable Parts And Salvage Operations, SEBF8068, "Cylinder Liners".Note: The connecting rods and caps must be etched with the number of the cylinder that is being used. The numbers must be on the same side of the rods and the caps as the bearing tab slots.Note: Lubricate the piston body assembly with clean engine oil around the zone (B) and the top of the piston body assembly prior to assembly into the cylinder block.Top Piston Ring (1)
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 ... 3.790 0.019 mm (0.1492 0.0007 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 with a bore size of 137.16 mm (5.400 inch), the clearance between the ends of the piston ring is the following value: ... 0.72 0.19 mm (0.028 0.008 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)Intermediate Piston Ring (2)
Install 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 ... 2.985 0.015 mm (0.1175 0.0006 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: ... 0.575 0.175 mm (0.0226 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)Oil Control Piston Ring (3)
Install the oil control ring. The gap in the spring must be 180 degrees away from the gap in the ring.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: ... 0.575 0.175 mm (0.0226 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)Piston Pin Bore
Note: Lubricate the piston pin with clean engine oil before assembly. (C) Dimensions for piston pin Diameter of the bore in the piston for the piston pin ... 50.815 0.005 mm (2.0006 0.0002 inch) Diameter of new piston pin ... 50.795 0.005 mm (1.9998 0.0002 inch) Clearance between pin and bore in piston ... 0.008 to 0.028 mm (0.0003 to 0.0011 inch) Maximum permissible worn clearance ... 0.05 mm (0.002 inch)