0385412 GEARCASE & BRG.ASSY. JOHNSON
100ESL72R, 125ESL72R, 85ESL72R
GEARCASE
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Number on catalog scheme: 1
BRP JOHNSON entire parts catalog list:
Information:
Installation Of Short Block Group Or Cylinder Block Service Group For 1100, 3100 and 3208 Naturally Aspirated Engines
In those applications where the original crankshaft is to be used again with a new cylinder block service group, check the crankshaft carefully to find the location of the oil supply passage for the No. 1 connecting rod bearing. (1) If the crankshaft has an oil passage (A) from the No. 1 (front) main bearing journal (1) to the No. 1 connecting rod bearing, it will be necessary to install a No. 1 main bearing with an upper half (2) that has a lubrication groove (B). (2) If the crankshaft has an oil passage (C) from No. 2 main bearing journal (3) to the No. 1 connecting rod bearing, it will be necessary to install a No. 1 main bearing that has an upper half similar to upper half (4), with no oil groove. (3) Install the correct upper half of the No. 1 (front) main bearing in the cylinder block. Locating tab (D) of the upper half of the No. 1 (front) main bearing, must fit in tab slot (5), in the center of the bore. Tab slots 6, 7, 8 and 9, for main bearings 2, 3, 4 and 5 are to the right of center as shown in the illustration. Install main bearings 2, 3, 4 and 5 in their correct location. Tighten the main bearing caps according to the Specifications in the Service Manual.Installation Of 5B1866 Plug And 9M575 Dowel On 1100, 3100 And 3208 Naturally Aspirated Engines
Sleeve Metering Fuel System
Compact (Scroll Type) Fuel System
Before installation of a short block group or the cylinder block service group, see the illustrations above to determine which type of fuel system is on the original engine. If the engine has a compact (scroll type) fuel system, do not install the dowel and plug. Lubrication to and from fuel injection pump and governor will be stopped.
(1) If the engine has a sleeve metering fuel system, install 9M575 Dowel (1) and 5B1866 Plug (2) to the dimension shown.(2) If the engine has a compact (scroll type) fuel system, do not install dowel (1) or plug (2).Installation Of Short Block Group Or Cylinder Block Service Group For 3208 Turbocharged Engines
A short block group with orifices (piston cooling jets) can be used as a replacement short block for those 3208 turbocharged engines that have orifices (piston cooling jets) in the cylinder block. The cylinder block service group has a replacement cylinder block assembly for 3208 turbocharged engines, but it is also necessary to use a cylinder block service kit. Use of the cylinder block service group makes it necessary to install either 8M3023 Orifices or 7M4593 Plugs, in the specific holes in the main bearing bore of the cylinder block. This instruction gives a method to check your old cylinder block to see if it is necessary to install the plugs or orifices, for your particular engine application.(A) Installation Of 7M4593 Plugs Or 8M3023 Orifices In 3208 Turbocharged Engines
(1) Look in the holes at each location (A) (crankshaft bearing bore) of the former cylinder block, to see if it has plugs (1) or orifices (2). If plugs were in the former cylinder block at locations (A), install the 7M4593 Plugs (1) in the new cylinder block. If orifices were in the former cylinder block at locations (A), use the orifice installation tool to install 8M3023 Orifices (2) in the new cylinder block.
If the correct parts (either 8M3023 Orifices or 7M4593 Plugs) are not installed in the new cylinder block according to the specific engine application, the result will be a short life for the engine, with possible piston seizure or bearing failure.
(2) Use a 6V7771 Plug Drive to install 7M4593 Plugs (1) in the cylinder block. Use a 6V7772 Orifice Driver to install 8M3023 Orifices (2) in the cylinder block.(3) After installation of 8M3023 Orifices (2) in a cylinder block, check the lubrication oil passage that goes through the center of each orifice. Use a piece of 1.8 Ø (0.07" Ø) drill rod to check the inside diameter of each orifice. The drill rod must be able to go all the way through each orifice. If it will not go through the hole in the orifice, remove that orifice and install a new one.(B) Installation Of 2W47 Cover Or 9N6487 Mount
(1) Look down in the vee of the old engine. Check the area at the rear of the cylinder block (1) [in the vee] to see if it looks like the illustration at location (A).(2) If the old engine is an early model 3208 Turbocharged Marine Engine, and the area at the rear of the old cylinder block vee looks like the illustration at location (A), install 5P7530 O-ring Seal (2) and 8M5260 O-ring Seal (3). Use 1A2029 Bolts with 5M2894 Washers to fasten 2W47 Cover (4) [cover (4) part number to be on top] in position over seals (2) and (3). Tighten the bolts to a torque of 43 7 (32 5 lb ft). (3) If the old engine is an early model 3208 Turbocharged Truck or Industrial Engine that has an area at the rear of the cylinder block vee that looks like the illustration at location (A), install a 5P7530 O-ring Seal (2) and an 8M5260 O-ring Seal (3). Use 1A2029 Bolts with 5M2894 Washers to fasten the new 9N6487 Turbocharger Mount (5) in position over seals (2) and (3). Tighten the bolts to a torque of 43 7 (32 5 lb ft).(4) On later model turbocharged engines where the area at the rear of the vee on the cylinder block does not look like location (A) [old block looks identical to new block at location (A)], use the same parts again that were used on your former cylinder block.
In those applications where the original crankshaft is to be used again with a new cylinder block service group, check the crankshaft carefully to find the location of the oil supply passage for the No. 1 connecting rod bearing. (1) If the crankshaft has an oil passage (A) from the No. 1 (front) main bearing journal (1) to the No. 1 connecting rod bearing, it will be necessary to install a No. 1 main bearing with an upper half (2) that has a lubrication groove (B). (2) If the crankshaft has an oil passage (C) from No. 2 main bearing journal (3) to the No. 1 connecting rod bearing, it will be necessary to install a No. 1 main bearing that has an upper half similar to upper half (4), with no oil groove. (3) Install the correct upper half of the No. 1 (front) main bearing in the cylinder block. Locating tab (D) of the upper half of the No. 1 (front) main bearing, must fit in tab slot (5), in the center of the bore. Tab slots 6, 7, 8 and 9, for main bearings 2, 3, 4 and 5 are to the right of center as shown in the illustration. Install main bearings 2, 3, 4 and 5 in their correct location. Tighten the main bearing caps according to the Specifications in the Service Manual.Installation Of 5B1866 Plug And 9M575 Dowel On 1100, 3100 And 3208 Naturally Aspirated Engines
Sleeve Metering Fuel System
Compact (Scroll Type) Fuel System
Before installation of a short block group or the cylinder block service group, see the illustrations above to determine which type of fuel system is on the original engine. If the engine has a compact (scroll type) fuel system, do not install the dowel and plug. Lubrication to and from fuel injection pump and governor will be stopped.
(1) If the engine has a sleeve metering fuel system, install 9M575 Dowel (1) and 5B1866 Plug (2) to the dimension shown.(2) If the engine has a compact (scroll type) fuel system, do not install dowel (1) or plug (2).Installation Of Short Block Group Or Cylinder Block Service Group For 3208 Turbocharged Engines
A short block group with orifices (piston cooling jets) can be used as a replacement short block for those 3208 turbocharged engines that have orifices (piston cooling jets) in the cylinder block. The cylinder block service group has a replacement cylinder block assembly for 3208 turbocharged engines, but it is also necessary to use a cylinder block service kit. Use of the cylinder block service group makes it necessary to install either 8M3023 Orifices or 7M4593 Plugs, in the specific holes in the main bearing bore of the cylinder block. This instruction gives a method to check your old cylinder block to see if it is necessary to install the plugs or orifices, for your particular engine application.(A) Installation Of 7M4593 Plugs Or 8M3023 Orifices In 3208 Turbocharged Engines
(1) Look in the holes at each location (A) (crankshaft bearing bore) of the former cylinder block, to see if it has plugs (1) or orifices (2). If plugs were in the former cylinder block at locations (A), install the 7M4593 Plugs (1) in the new cylinder block. If orifices were in the former cylinder block at locations (A), use the orifice installation tool to install 8M3023 Orifices (2) in the new cylinder block.
If the correct parts (either 8M3023 Orifices or 7M4593 Plugs) are not installed in the new cylinder block according to the specific engine application, the result will be a short life for the engine, with possible piston seizure or bearing failure.
(2) Use a 6V7771 Plug Drive to install 7M4593 Plugs (1) in the cylinder block. Use a 6V7772 Orifice Driver to install 8M3023 Orifices (2) in the cylinder block.(3) After installation of 8M3023 Orifices (2) in a cylinder block, check the lubrication oil passage that goes through the center of each orifice. Use a piece of 1.8 Ø (0.07" Ø) drill rod to check the inside diameter of each orifice. The drill rod must be able to go all the way through each orifice. If it will not go through the hole in the orifice, remove that orifice and install a new one.(B) Installation Of 2W47 Cover Or 9N6487 Mount
(1) Look down in the vee of the old engine. Check the area at the rear of the cylinder block (1) [in the vee] to see if it looks like the illustration at location (A).(2) If the old engine is an early model 3208 Turbocharged Marine Engine, and the area at the rear of the old cylinder block vee looks like the illustration at location (A), install 5P7530 O-ring Seal (2) and 8M5260 O-ring Seal (3). Use 1A2029 Bolts with 5M2894 Washers to fasten 2W47 Cover (4) [cover (4) part number to be on top] in position over seals (2) and (3). Tighten the bolts to a torque of 43 7 (32 5 lb ft). (3) If the old engine is an early model 3208 Turbocharged Truck or Industrial Engine that has an area at the rear of the cylinder block vee that looks like the illustration at location (A), install a 5P7530 O-ring Seal (2) and an 8M5260 O-ring Seal (3). Use 1A2029 Bolts with 5M2894 Washers to fasten the new 9N6487 Turbocharger Mount (5) in position over seals (2) and (3). Tighten the bolts to a torque of 43 7 (32 5 lb ft).(4) On later model turbocharged engines where the area at the rear of the vee on the cylinder block does not look like location (A) [old block looks identical to new block at location (A)], use the same parts again that were used on your former cylinder block.
Parts gearcase JOHNSON:
0385413