0383236 JOHNSON PISTON ASSEMBLY, Less ring, std

1. Put identification on six hoses (1). Disconnect the six hoses from the shutoff control.2. Disconnect the drain tube from the bottom on the shutoff control. 3. Remove nine bolts (2) and lockwasher. Remove shutoff control (3) from the oil pump.4. Install a new gasket between the shutoff control and the oil pump.
Be sure the splines on the shutoff control drive shaft are in alignment with the splines in the oil pump drive coupling.
5. Install the shutoff control on the oil pump with nine bolts (2) and lockwashers.6. Connect the tube to the bottom of the shutoff control.7. Connect six hoses (1) to the shutoff control.
The top of the engine oil pump must be filled with two quarts (1.9 liter) of engine oil before start-up if the shutoff control oil sump has been drained. Remove the fitting on the pump and add the oil.
Disassemble Shutoff Control Group
start by:a) remove shutoff control group 1. Remove tubes (1) and (2) from the shutoff control group. 2. Remove eight bolts (3). Remove actuator valve (4) and pressure control valve (5).
There is spring pressure on cover (6). Use caution when the cover is removed.
3. Remove eight bolts (7) and cover (6) from the actuator valve. 4. Put identification on four springs (9) and four valves (8) for assembly. Remove the springs and valves from the valve body. Later controls use three springs (9) and three valves (8). 5. Put identification on two valve assemblies (14) for assembly. Do not mix the position of valve assemblies (14). Remove two valve assemblies (14) from pressure control valve body. Remove plug (13), valve (12) and spring (11) from the body. Remove valve assembly (10) from the body. 6. Loosen the nut and remove knob (15) and nut from valve (10). Remove adapter (16) and spring (18) from the valve. 7. Remove lip type seal (17) from adapter (16). 8. Remove ten bolts (18) and washers. Remove pump assembly (19) from the body. 9. Remove retainer ring (20) with tool (A). Remove the washer, oil pump housing (19) and gerotor assembly from cover (21). 10. Remove gerotor assembly (22) from pump housing (19). Remove retainer ring (23) with tool (A). Remove the seat, spring and plunger from the housing. 11. Remove key (25), carrier assembly (24) and washer from cover (21). 12. Remove speed sensing valve (27), spring (26) and seat from the body. 13. Remove retainer ring (30), race (29), bearing (28) and race (31) from valve (27).
Spring pressure is on cover (32). Use caution when the cover is removed.
14. Remove four bolts (33), washers and cover (32) from the housing. Remove the spring and seat from the cover.Assemble Shutoff Control Group
1. Install a new gasket (4) between cover (1) and the body. Install a seat (3) in cover (1) and on the body as shown. Install spring (2) in seat and install the cover with four bolts and washers. 2. Install race (9), bearing (6) and race (7) on speed sensing valve (5) with retainer ring (8). 3. Install seat (10), spring (11) and speed sensing valve assembly (5) in the body as shown. 4. Install washer (13) on cover (14). Install carrier assembly (12) in the cover as shown and install the key in the carrier assembly shaft.5. Clean the pump cover and housing to remove old gasket material. Put 6V1541 Quick Cure Primer on the cover only and let dry. 6. Install O-ring seal (15) in oil pump housing (20). Put a thin layer of SAE 30 oil on seal (15) and the bore in the housing. Install plunger (16), spring (21) and seat (17) in the housing. Install retainer ring (19) with tool (A). Install gerotor assembly (18) in the housing.8. Put a thin layer of 6V6640 Sealant on the oil pump housing only. Leave approximately .040-.078 in. (1 - 2mm) gap around the pump pocket. 9. Install the cover assembly on the housing assembly. Be sure the key in the carrier shaft is in alignment with the groove (slot) for key in the gerotor assembly. Install washer (23) and retainer ring (22) with tool (A).
Do not turn the faces relative to each other. This will avoid smearing the gasket material.
10. Install a new gasket between the body and pump assembly. Install the pump assembly on the body with ten bolts and washers. 11. Install the lip type seal in adapter (24) with tooling (B). Install the seal with the seal lip toward the inside of the pressure control valve. Put a thin layer of SAE 30 oil on the seal lip. 12. Install spring (29), adapter (24), nut (27) and knob (25) on valve (26). Install O-ring seal (28) on the adapter. 13. Install three O-ring seals (35) on valve assemblies (31) and (36). Install the valve assemblies in the body. Tighten the valve assemblies to a torque of 43 3 lb.ft. (58 4 N m). Install O-ring seal (33) on plug (34). Install spring (30), valve (32) and plug (34) in the body. Install valve assembly (26) in the body. 14. Install four valves (37) in the actuator valve body. Install four springs (38). Install a new gasket between the body and cover (39). Install the cover on the body with eight bolts and washers. Later controls use three springs (38) and three valves (37). 15. Install a new gasket between the body and pressure control valve assembly (41). Put the pressure control valve in position on the body. Install a new gasket between the pressure control valve and actuator valve assembly (40). Fasten the actuator valve and pressure control valve to the body with eight bolts and washers. 16. In