5040484 EVINRUDE * COTTER

3. Disconnect fuel lines (2) and remove fuel manifold (3).4. Remove a section of water manifold (1) and the gaskets. If it is necessary to work on cylinder head assembly number 2,4, or 6, it will be necessary to move or remove the instrument panel group. In many cases, the instrument panel group can be unbolted from its support, suspended by use of wire or rope so that no lines or wire connections have to be disconnected. 5. Remove elbow (6) and the gasket.6. Remove a section of exhaust manifold (4) and the gasket.7. Remove inlet elbow (5) and the gasket. 8. Remove the access cover, the bolt, and cap (9) to disconnect rod assembly (8) from the fuel control shaft. Remove the lever assembly and rod assembly (8) as a unit when removing the fuel injector.9. Remove the fuel injector. See the topic, Remove Fuel Injector.10. Remove valve cover base (7), the gasket, and the O-ring seals. 11. Attach tooling (B) and a hoist to cylinder head assembly (10). Remove all bolts (11) and (12). Remove cylinder head assembly (10). The weight of the cylinder head assembly is 49 kg (108 lb).12. Remove the spacer plate. See the topic, Remove Spacer Plate. The following steps are for installation of the cylinder head assembly. A new spacer plate gasket must be installed when the cylinder head is removed.13. Install the spacer plate. See the topic, Install Spacer Plate.
Before installation of the cylinder head assembly, be sure the 4D0514 Plug is installed at location (X).
14. Attach tooling (B) and a hoist to cylinder head assembly (10). Put the cylinder head assembly in position. 15. Put 5P3931 Anti-Seize Compound on the threads of cylinder head bolts (11). Install the cylinder head bolts and washers. Tighten the bolts in the following sequence:a. Tighten all of the bolts to a torque of 30 5 N m (22 4 lb ft).b. Tighten bolts 1 through 8 in number sequence to a torque of 270 35 N m (200 26 lb ft).c. Tighten bolts 1 through 8 in number sequence to a torque of 450 20 N m (330 15 lb ft).16. Install the O-ring seals, the gasket, and valve cover base (7). Install the lever assembly and rod assembly (8) as a unit when installing the fuel injector.17. Install the fuel injector. See the topic, Install Fuel Injector.18. Connect rod assembly (8) to the fuel control shaft and install cap (9), the bolt, and the access cover.19. Install the gasket and inlet elbow (5).
Tighten the individual exhaust manifold section to the cylinder head first. Then, tighten the individual exhaust manifold section to the other manifold sections. This procedure will prevent exhaust manifold damage caused by misalignment.
20. Install the gasket and exhaust manifold section (4).21. Install the gasket and elbow (6).22. Install the gaskets and water manifold section (1).23. Install fuel manifold (3) and connect fuel lines (2).24. Turn on the fuel supply.25. Fill the cooling system with coolant to the correct level. See the Maintenance Manual.