0381575 JOHNSON GEARCASE ASSY., Less driveshaft and pump

Illustration 1 g03497816
Front view of engine
Table 1
Specification for 383-2091 Cylinder Block Gp
Item Qty Part Specification Description
- During assembly, bottom of the plate, top of the block, and both the sides of the gasket plate must be free of all visible fuel, oil, water and gasket adhesives, assembly compounds, or any other contaminates.
1 3 4W-4813 Plug Torque to 100 15 N m (74 11 lb ft).
2 4 5F-9657 O-Ring Seal Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
3 14 101-1198 Camshaft Bearing All centerlines through oil holes in the camshaft bearings and the camshaft bearing junctions must be positioned as shown in Illustration 1 on each side of cylinder block.
Oil holes must be positioned from horizontal at an angle (D) of 20 5 degrees as shown in Illustration 1.
Bore in the cylinder block for camshaft bearing is 98.00 0.02 mm (3.858 0.001 inch).
4 8 6V-3348 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.
A 24 8T-0099 Dowel Extension of the dowel from the top face of the cylinder block is 21.0 1.0 mm (0.83 0.04 inch).
C 12 197-7008 Dowel Extension of the dowel from the top face of the cylinder block is 21.0 1.0 mm (0.83 0.04 inch).
E 7 223-1696 Crankshaft Bearing Cap Width of the crankshaft bearing cap is 340.030 0.015 mm (13.3870 0.0006 inch).
Width of cylinder block for main bearing cap is 339.985 0.015 mm (13.3852 0.0006 inch).
F - - New dimension from centerline of crankshaft bearing bore to the top of the cylinder block is 586 mm (23.071 inch).
G - - New dimension from centerline of crankshaft bearing bore to bottom of cylinder block (pan rails) is 230 mm (9.1 inch).
H - - Bore in the cylinder block for the main bearings is 169.742 0.020 mm (6.6827 0.0008 inch).
Illustration 2 g03497817
Section B-B
Table 2
Item Qty Part Specification Description
J 1 7N-2047 Dowel Extension of the dowel from the rear face of the cylinder block is 6.0 0.5 mm (0.24 0.02 inch).
K 1 7N-2047 Dowel Extension of the dowel from the front face of the cylinder block is 6.0 0.5 mm (0.24 0.02 inch).
L 2 4N-0683 Dowel Extension of the dowel from the rear face of the cylinder block is 19.0 1.0 mm (0.75 0.04 inch).
M 2 7N-2044 Dowel Extension of the dowel from the front face of the cylinder block is 40.0 1.0 mm (1.57 0.04 inch).
Illustration 3 g03497818
Table 3
Item Qty Part Specification Description
5 12 352-6061 Liner Seal Assemble dry seals on clean and dry liner grooves.
Before assembly, cover seals with either P-80 Rubber Lubricant Emulsion or liquid soap.
6 36 7N-2046 O-Ring Seal Before assembly, cover seals with either P-80 Rubber Lubricant Emulsion or liquid soap.
7 28 7X-7925 Bolt Use the following procedure in order to tighten the crankshaft bearing cap bolts:
1. Before assembly, lubricate the threads completely with clean engine oil.
2. Hand tighten the bolts in the tapped holes.
3. Tighten the bolts in the numerical sequence as shown in Illustration 3 to 190 14 N m (140 10 lb ft).
4. Again, tighten the bolts for an additional angle of 180 5 degrees.