0438397 JOHNSON CARBURETOR REPAIR KIT

Hot oil and components can cause personal injury.Do not allow hot oil or components to contact skin.
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.Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.Dispose of all fluids according to local regulations and mandates.
Drain the engine oil into a suitable container for storage or disposal.
Illustration 1 g00516290
Typical example
Remove bolts (2) and the washers. Remove sound suppression cover (1), if equipped.
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Typical example
Remove the following items from the cylinder block: bolts (5), the washers, the isolators and the isolator sleeves.
Remove engine oil pan (6) and the gasket.
Remove pipe plug (3) and drain plug (4) with the O-ring seal, if necessary.Installation Procedure
Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     -         -    
(-) Loctite 5900     -    
B     -     Loctite 243     -    
C     -     Loctite 243     -    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Inspect the condition of the gasket. Replace the gasket, if necessary.
Clean the mating surface of the engine oil pan and the cylinder block.Note: Apply Tooling (A) to the edges of the cylinder block and to the seams prior to installation.
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Typical example
Place the gasket and engine oil pan (6) on the cylinder block.
Install the following items: isolator sleeves, isolators, bolts (5), and the washers.Note: Perform the following procedure in order to eliminate the possibility of an oil leak from the bolt for the engine oil pan:
Illustration 4 g01022239
Note: The path of the oil leak is through the threads of bolt (8) for the engine oil pan. The third bolt from the front of engine block (7) on the right side of the engine is the suspect bolt.
Clean the bolt hole and dry the bolt hole.
Clean the oil pan bolt and dry the oil pan bolt.
Apply Tooling (B) or Tooling (C) to the threads of the bolt.
Install the oil pan bolt and tighten the bolt to a torque of 55 10 N m (40 7 lb ft).
Wipe off excess Tooling (A) from all gasket joints. Use a flat, straight tool in order to remove the sealant.
Apply Tooling (C) to pipe plug (3). Install pipe plug (3). Tighten the plug to a torque of 80 11 N m (60 8 lb ft).
Install drain plug (4) and the O-ring seal. Tighten the plug to a torque of 70 15 N m (50 11 lb ft).
Illustration 5 g00516290
Typical example
Position the sound suppression cover (1) on the engine oil pan and install six bolts (2) with the washers.
Fill the engine with oil to the correct level. See the Operation and Maintenance Manual for the correct filling procedure.