0383003 JOHNSON STARTER ASSEMBLY COMPLETE

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.
Illustration 1 g02823478
Remove oil drain plug (6). Drain the engine oil into a suitable container for storage or disposal.
Remove sealing washer (5) (not shown) from oil drain plug (5).
Remove two M10 bolts (7) and remove M8 bolts (3) from engine oil pan (4). Note: Support the weight of the engine oil pan.
Remove spacer (2) from the engine oil pan.
Remove the engine oil pan from the cylinder block.
Remove gasket (1) (not shown).
Illustration 2 g02823476
If necessary, follow Step 7.a through Step 7.d in order to remove oil suction pipe (9) from the cylinder block.
Remove Allen head cap screw (10) from oil suction pipe (9).
Remove bolts (11) from the oil suction pipe.
Remove the oil suction pipe from the cylinder block.
Remove O-ring (8) from oil suction pipe (9). Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A - Technologic 15 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that all components are clean and free from damage. If necessary, replace any components that are worn or damaged.
Illustration 3 g02823476
If necessary, follow Step 2.a through Step 2.f in order to install oil suction pipe (9).
Install new O-ring seal (8) to oil suction pipe (9).
Install the oil suction pipe to the cylinder block.
Apply Tooling (A) onto the threads of Allen head cap screw (10). Install the Allen head cap screw to the oil suction pipe.
Apply Tooling (A) onto the threads of bolts (11). Install bolts (11) to the oil suction pipe support.
Tighten Allen head cap screw (10) to a torque of 10 N m (89 lb in).
When a M8 bolts are installed, tighten bolts (11) to a torque of 25 N m (221 lb in). When a M10 bolts are installed, tighten bolts (11) to a torque of 45 N m (33 lb ft).
Clean the mating surface of the cylinder block.
Illustration 4 g02823478
Illustration 5 g02826556
Position gasket (1) (not shown) onto engine oil pan (4).
Position spacer (2) onto the engine oil pan.
Position the engine oil pan onto the cylinder block. Use a suitable tool to support the weight of the engine oil pan.
Install bolts (3) and install bolts (7) finger tight.
Tighten bolts (3) and bolts (7) in the sequence that is shown in Illustration 5. Tighten bolts (3) to a torque of 25 N m (221 lb in).Tighten bolts (7) to a torque of 45 N m (33 lb ft).
Install a new sealing washer (5) to oil drain plug (6).
Install oil drain plug (6) to the engine oil pan . Tighten the oil drain plug to a torque of 50 N m (37 lb ft).
Fill the engine oil pan to the correct level. Refer to Operation and Maintenance Manual, "Engine Oil and Filter - Change" for the correct procedure.