0209501 JOHNSON OWNER'S MANUAL

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 241-4232 Alignment Tool 1
B - Multipurpose Grease 1
C 8T-5096 Dial Indicator 1
- Magnetic Base and Stand 1
(1) C1.5 and C2.2 engines
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
If the front housing is not installed, do not turn the crankshaft. Damage to the engine may occur.
Ensure that all components of the engine oil pump are clean and free from wear and damage. Refer to System Operation, Testing and Adjusting,, "Engine Oil Pump - Inspect" and Specifications,, "Engine Oil Pump" for the correct information. Replace the complete assembly of the engine oil pump if any of the components are worn or damaged.
Illustration 1 g03331749
If necessary, follow Step 2.a through Step 2.e In order to install idler hub (1) to the cylinder block.
Ensure that the recess in the cylinder block in Position (W) is clean and free from wear and damage.
Install the pin of Tooling (A) to the cylinder block.
Position idler hub (1) into Tooling (A). Align Tooling (A) with pin of Tooling (A) and the recess in the cylinder block.
Use a hammer to strike Tooling (A). Drive idler hub (1) into the cylinder block until Tooling (A) contacts the front face of the cylinder block.
Remove both part of Tooling (A).
Illustration 2 g03794163
Position a new gasket (15) on the cylinder block. Align the gasket with the dowels in the cylinder block.
Align plate (14) with the dowels in the cylinder block and install the plate.
Install bolts (17) hand tight.
Tighten bolts (17) to a torque of 10 N m (89 lb in).
Illustration 3 g03331719
Illustration 4 g03794643
Lubricate thrust washer (2) with clean engine oil.
Install thrust washer (2) onto idler hub (1).
Improper assembly of parts that are spring loaded can cause bodily injury.To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Apply Tooling (B) to the faces of inner rotor (4) and to the vanes of idler gear (3).
Align timing Marks (X) on idler gear (3) with the timing marks on camshaft gear (19) and crankshaft gear (20). Install idler gear (3) onto idler hub (1).
Install inner rotor (4) to idler gear (3).
Personal injury can result from the release of the spring force.The drive shaft, the piston, and the drive gear are under spring force.Use a press to slowly release the spring force before the components are removed.
Install the following components from idler hub (1) collar (8), spring (7), shim (6) and oil pump cover (5).Refer to Illustration 3.
Install retaining ring (9) on idler hub (1).
Illustration 5 g03332115
Use Tooling (C) to measure the end play of the engine oil pump. Refer to Specifications, "Engine Oil Pump" for the correct information.
Illustration 6 g03331717
If necessary, follow Step 15.a through Step 15.e In order to install oil strainer (13) and suction pipe (11).
Install a new O-ring seal (10) onto suction pipe (11).
Install suction pipe (11) in the cylinder block. Ensure that the O-ring seal is not damaged as the suction pipe is installed.
Position oil strainer (13) onto the cylinder block. Ensure that the oil strainer and the suction pipe are correctly positioned.
Install bolt (12) hand tight.
Tighten bolts (12) to a torque of 11 N m (97 lb in).End By:
Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install" for the correct procedure.
Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Instal