0384009 EVINRUDE EXTENSION KIT ASSY.-5' 5 INCH LONGER PARTS

3. Remove fuel lines (1) and bracket (2) from the engine. 4. Remove bolts (3) and (5) to remove adapter (4) and tube (6) from the engine. 5. Remove bolts (7) to disconnect elbow (8) from the oil pump. 6. Remove bolts (9) to remove oil pump (10) and adapter (11) from the oil pump drive. The weight of the oil pump is 39 kg (85 lb.).Install Oil Pump
1. Make sure the O-ring seals are in position on adapters (3), (4) and elbow (2). Put clean engine oil on the seals. The oil pump shaft must turn by hand, and the pump must have oil for lubrication before it is installed.2. Put oil pump (1) and adapter (4) in position in the oil pump drive. Make sure the splines of the oil pump are correctly engaged with the splines of the oil pump drive. Install the bolts that hold oil pump (1) and adapter (4) in position. 3. Install the bolts that connect elbow (2) to oil pump (1). 4. Make sure O-ring seal (9) is in position on tube (8), and put clean engine oil on the seal.5. Put tube (8) and adapter (6) with the gaskets for tube (5) and water pump (7) in position, and install the bolts. 6. Install fuel lines (10) and bracket (11) on the engine.7. Fill the engine with oil to the correct level. See the Maintenance Manual.8. Fill the cooling system with coolant to the correct level. See the Maintenance Manual.End By:a. install fuel transfer pumpDisassemble Oil Pump
Start By:a. remove oil pump The pump shown in the illustrations is for the 3508 Engine. 1. Remove adapter assembly (1) from the pump.
Cover (2) has spring tension on it. Loosen the bolts that hold it slowly and the same amount to remove the tension on the cover.
2. Remove the bolts, cover (2), gasket (3), spring (4) and valve spool (5) from the pump. 3. Remove cover assembly (6) and the gasket from the pump. 4. Remove cover assembly (7) from the pump. 5. Use tooling (A) to remove bearings (8) from cover assembly (7). 6. Remove shaft assemblies (10) from body assembly (9). 7. Use a press to remove gears (11) from the shaft assemblies. 8. Use tooling (A) to remove bearings (12) from body assembly (9).Assemble Oil Pump
The pump shown in the illustration is for the 3508 Engine. 1. Make an alignment of bearings (1) so the joints are 45 15° from a line through the center of the bearing bores as shown.2. Use tooling (A) to install bearings (1) in the body assembly until they are 1.5 0.5 mm (.06 .02 in.) below the gear bore in the body assembly. Check the inside diameter of the bearings after installation. The diameter must be 31.811 0.013 mm (1.2524 .0005 in.). 3. Heat gears (2) to a maximum temperature of 315°C (600°F).4. Install the gears on shaft assemblies (3) until they are 34.0 0.5 mm (1.34 .02 in.) from the cover end of the shaft assemblies to the face of the gears and 47.0 0.5 mm (1.85 .02 in.) from the fuel pump drive end of shaft assembly (4). 5. Install shaft assemblies (3) and (4) in the body assembly. 6. Make sure dowels (5) and (8) are installed in cover assembly (6) so they extend 6.0 0.5 mm (.24 .02 in.) above the surface of the cover assembly.7. Use tooling (A) and install bearings (7) in cover assembly (6) with the joints of the bearings in the positions as shown. 8. Put cover assembly (6) in position, and tighten the bolts to hold it to the body assembly. 9. Make sure the two pins in cover assembly (9) are installed so they extend 6.0 1.0 mm (.24 .04 in.) above the surface of the cover assembly. Install the gasket and cover assembly (9) on the pump. 10. Put clean engine oil on valve spool (13). Install valve spool (13), spring (12), gasket (11), cover (10) and the bolts on the pump body. 11. Install the gasket and adapter assembly (14) on the pump body.End By:a. install oil pump