0389556 JOHNSON POWERHEAD GASKET SET, 115, 140 HP

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Strap Wrench 1
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.Dispose of all fluids according to local regulations and mandates.
In order to remove a cast iron oil pan, the engine must be removed from the machine. The engine should be mounted in a suitable stand and placed in the inverted position.
Illustration 1 g02475578
Use Tooling (A) in order to remove engine oil filter (5). Remove plug (3) and drain the engine lubricating oil. Remove O-ring seal (4) (not shown) from plug (3). Refer to Operation and Maintenance Manual, "Engine Oil and Filter - Change" for correct procedure.
Remove breather hose (1) from the clip. Position the breather hose away from the engine oil pan.
Loosen nut (6) and remove tube assembly (2). Remove O-ring seal (7) and seal (8) from the tube assembly.
Illustration 2 g02475581
Remove nuts (9) and bolts (10) from engine oil pan (11). Note: The bolts are different lengths. Note the position of the different bolts.
Attach a suitable lifting device to engine oil pan (11). Support the weight of the engine oil pan. The engine oil pan weighs approximately 41 kg (90 lb).
Use the lifting device to remove engine oil pan (11) from the cylinder block.
Remove gasket (12) from the cylinder block. Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A - Loctite 5900 -
B - Loctite 243 -
C - Straight Edge 1 Note: In order to install a cast iron oil pan, the engine must be removed from the machine.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the face of the cylinder block is clean and free from damage. Inspect the studs in the cylinder block for damage. If necessary, replace the studs.
Ensure that the engine oil pan is clean and free from damage.
Illustration 3 g02475645
Illustration 4 g02475646
Apply a bead of Tooling (A) to Positions (Y) on the cylinder block. Note: If the bridge piece for the cylinder block has just been installed, the engine oil pan must be installed before Tooling (A) has cured.
Illustration 5 g02475581
Illustration 6 g02475647
Align a new gasket (12) with the studs in the cylinder block. Install the gasket to the cylinder block.
Attach a suitable lifting device to engine oil pan (11). The engine oil pan weighs approximately 41 kg (90 lb).
Use the lifting device to align engine oil pan (11) with the studs in the cylinder block. Install the engine oil pan to the cylinder block. Remove the lifting device from the engine oil pan.
Install nuts (9) and bolts (10) finger tight.
Align the rear face of engine oil pan (11) to the rear face of cylinder block (13) on both sides. Use Tooling (C) and a feeler gauge in order to check the alignment between the engine oil pan and the cylinder block. The maximum step that is allowed between the cylinder block and the sump is 0.1 mm (0.004 inch).
Tighten bolts (9) and nuts (10) to a torque of 22 N m (16 lb ft). Refer to Specifications, "Engine Oil Pan" for the correct tightening sequence.