0391634 EVINRUDE WATER PUMP REPAIR KIT (includes impeller hous ing)

Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Ensure that the engine lubricating oil is drained. Refer to Operation and Maintenance Manual, "Engine Oil and Filter - Change" for the correct procedure.
The engine should be mounted in a suitable stand and placed in the inverted position.
Illustration 1 g01478088
Typical example
Disconnect breather hose (1) from clip (6). Position the breather hose away from the engine oil pan. Note: Identify the position and orientation of the tube assembly before removal.
Remove the assembly of the dipstick tube. Loosen nut (3) and remove tube assembly (2). Remove seal (4) from the tube assembly.
Mark the position of clip (6). Refer to Illustration 1. Loosen the bolt that secures the clip and remove the clip.
Illustration 2 g01251978
Typical example
Remove nuts (10) and bolts (9). Note: The bolts are different lengths. Note the position of the different bolts.
Attach a suitable lifting device to engine oil pan (8). Support the weight of the engine oil pan. The engine oil pan weighs approximately 41 kg (90 lb).
Use the lifting device to remove engine oil pan (8) from the cylinder block.
Remove gasket (7) from the cylinder block.
If necessary, remove drain plug (5). Remove O-ring seal (11) from oil drain plug (5). Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A - Loctite 5900 -
B - Loctite 243 -
C - Straight Edge 1 Note: In order to install a cast iron oil pan, the engine must be removed from the machine.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the face of the cylinder block is clean and free from damage. Inspect the studs in the cylinder block for damage. If necessary, replace the studs.
Ensure that the engine oil pan is clean and free from damage.
Illustration 3 g01251763
Typical example
Illustration 4 g01803754
Typical example
Apply a bead of Tooling (A) to Positions (Y) on the cylinder block. Note: If the bridge piece for the cylinder block has just been installed, the engine oil pan must be installed before Tooling (A) has cured.
Illustration 5 g01251978
Typical example
Align a new gasket (7) with the studs in the cylinder block. Install the gasket to the cylinder block.
Attach a suitable lifting device to engine oil pan (8). The engine oil pan weighs approximately 41 kg (90 lb).
Use the lifting device to align engine oil pan (8) with the studs in the cylinder block. Install the engine oil pan to the cylinder block. Remove the lifting device from the engine oil pan.
Install bolts (9) and nuts (10) finger tight. Install clip (6).
Illustration 6 g01251982
Typical example
Align the rear face of engine oil pan (8) to the rear face of cylinder block (12). Use Tooling (C) and a feeler gauge in order to check the alignment between the engine oil pan and the cylinder block. The maximum step that is allowed between the cylinder block and the sump is 0.1 mm (0.004 inch).
Tighten bolts (9) and nuts (10) to a torque of 22 N m (16 lb ft). Refer to Specifications, "Engine Oil Pan" for the correct tightening sequence.
Illustration 7 g01251772