0207003 EVINRUDE APPLIQUE, Evinrude

Connecting Rods and Pistons
The C-10 engine uses a 1U-9593 Cylinder Pack Puller with a 1U-9897 Bridge , and a 1U-6319 Socket to remove a cylinder pack (connecting rod and piston) from the block. Use either the 1U-9788 Nylon Brush for reconditioning the cylinder liners. Use the 1U-9787 Flexible Hone for reconditioning the cylinder liners.Use the 4C-3601 Piston Ring Expander in order to remove the piston rings. Use the 4C-3601 Piston Ring Expander in order to install the piston rings. Use the 1U-6684 Piston Ring Compressor in order to install the pistons into the cylinder block. Tighten the connecting rod nuts in the step sequence that follows:
Put 4C-5593 Anti-Seize Compound Thread Lubricant on bolt threads and contact surfaces of nut and cap.
Install the connecting rod nuts according to the following procedure:Tighten the connecting rod nuts to the following torque: ... 130 7 N m (95 5 lb ft)
Put a mark on each nut and end of bolt.
Tighten each nut by the following method:Tighten the nut: ... 60 5 degreesThe connecting rod bearings fit tightly in the bore in the rod. If the bearing joints are worn, check the bore size. This can be an indication of wear because of a loose fit. Connecting Rod and Main Bearings
Connecting Rod Bearings
Connecting rod bearings are available with 0.508 mm (.0200 inch) and 0.762 mm (.0300 inch) smaller inside diameter than the original size bearings. These bearings are for crankshafts that have been ground.Main Bearings
Main bearings are available with 0.508 mm (.0200 inch) and a 0.762 mm (.0300 inch) smaller inside diameter than the original size bearings. These bearings are for crankshafts that have been ground.Main bearings are also available with a larger outside diameter than the original size bearings. These bearings are used for the cylinder blocks with the main bearing bore that is made larger than the bore's original size. The size that is available has a 0.508 mm (.0200 inch) outside diameter that is larger than the original size bearings.The Special Instruction, SMHS7606 gives the instructions for the use of 1P-4000 Line Boring Tool Group . The 1P-4000 Line Boring Tool Group is used in order to check the alignment of the main bearing bores. The 1P-3537 Dial Bore Gauge Group can be used to check the size of the bore. The Special Instruction, GMGO0981 gives the instructions for the use of 1P-3537 Dial Bore Gauge Group .Cylinder Block
Table 1
Tools Needed    
Part Number     Part Name     Quantity    
1P-3537     Dial Bore Gauge Group     1    
Illustration 1 g00285686
1P-3537 Dial Bore Gauge Group If the main bearing caps are installed without bearings, the bore in the block for the main bearings can be checked. Tighten the nuts that hold the caps to the torque that is shown in the Specifications, "Cylinder Block". Alignment error in the bores must not be more than 0.08 mm (.003 inch). The 1P-3537 Dial Bore Gauge Group can be used to check the size of the bores. The Special Instruction, GMGO0981 is with the group.Cylinder Liner Projection
Table 2
Tools Needed    
Part Number     Part Name     Quantity    
8T-0455     Liner Projection Tool Group     1    
Clean the cylinder liner flange and the cylinder block surface. Remove any nicks on the top of the cylinder block.
Table 3
Needed Components    
Item     Part Number     Description     Quantity for One Cylinder     Quantity for Six Cylinders    
1     8T-4193     Bolt     6     36    
2     2S-5658     Washer     6     36    
3     8F-1484     Washer     6     36    
4     7K-1997     Washer     6     36    
Illustration 2 g00441535
Location of the Components (1) Bolt (2) Washer (3) Washer (4) Washer
The illustration and the chart identify the components that are required. An 8T-0455 Liner Projection Tool Group is also required.
The components should be assembled in the order that is shown in 2. The 7K-1977 Washer (4) is made of a cotton fabric that is impregnated with resin. The washer will not damage the sealing surface of the cylinder block. Note: Inspect the washer before measuring the liner projection. Replace the washer if the washer is worn or damaged.
Tighten bolts (1) evenly according to the following procedure:First tighten each bolt to the following torque. ... 27 N m (20 lb ft)Then tighten each bolt to the following torque. ... 54 N m (40 lb ft)Then tighten each bolt to the following torque. ... 68 N m (50 lb ft)Again tighten each bolt to the fo