5040220 EVINRUDE BAND LEAD WIRE 158

1. Remove oil tube (1) from the engine.2. Fasten a hoist to support (2) with tooling (A) and remove support (2) from the drive housing. The weight of the support is 102 kg (225 lb.). 3. Remove elbow (3) and tube (4) as a unit from the engine. 4. Remove the bolts and use tooling (B) to remove shaft (6) and idler gear (5) from the drive housing. 5. If necessary, use tooling (C) to remove the bearing from idler gear (5). 6. Remove washer (7) from the inside of the drive housing. 7. Remove bolt (9) and washer to remove clip (8) from the drive housing. 8. Remove cover (11) from the drive housing.9. Remove all of the bolts that hold the oil pan to the engine. Install 3/8"-16 NC guide bolts in each side of the oil pan. Fasten a hoist to the engine and lift the engine approximately 12 mm (0.5 in.) off of the oil pan. Put two 50 mm wide x 100 mm long x 6 mm thick (2 in. wide x 4 in. long x 1/4 in. thick) plates in position between the cylinder block and the oil pan on each side of the engine. Lower the engine on the plates and remove the hoist. The weight of the 3512 Engine is approximately 5443 kg (12,000 lb.). The weight of the 3508 Engine is 4445 kg (9800 lb.).
Fuel control linkage (10) must be moved for clearance to pull the front drive housing from the engine or damage to parts can be the result.
10. Fasten a hoist to front drive housing (12) with tooling (A). Remove bolts (13) and the remainder of the bolts that hold housing (12) in position. Remove front drive housing (12) from the engine. The weight of the housing is 209 kg (460 lb.).Install Front Drive Housing
1. Put the housing gasket in position on the front of the cylinder block. Install two 5/8"-11 NC guide bolts (1) in the cylinder block. 2. Fasten a hoist to front drive housing (2) with tooling (A). Put housing (2) in position on the guide bolts and install the bolts to hold it in position. Remove the guide bolts and install the remainder of the bolts. Tighten all of the bolts evenly and cut the housing gasket even with the bottom of the cylinder block.3. Fasten a hoist to the engine and lift the engine enough to remove the plates between the cylinder block and the oil pan. If the oil pan gasket is damaged, the engine will have to be removed from the oil pan to make a replacement of the gasket. Lower the engine on the oil pan and remove the guide bolts of the oil pan. Install all of the bolts that hold the oil pan to the engine. 4. Put clean engine oil on the O-ring seals and install cover (3) on the drive housing. 5. Put washer (4) in position inside the drive housing. 6. Use tooling (B) and a press to install the bearing in idler gear (5). Check the bore in the bearing after assembly. The bore in the bearing must be 90.00 0.06 mm (3.543 .002 in.). 7. Put clean engine oil on the O-ring seal on shaft (6). Install idler gear (5) and shaft (6) in the front drive housing. 8. Make sure the gasket and seals are in position and install aftercooler water line (7) on the engine. Install clip (8) on the drive housing.9. Install oil tube (9) on the engine. 10. Fasten a hoist to support (10) with tooling (A) and put it in position on the front drive housing. Install the bolts to hold the support in position. Anytime the front crankshaft seal and wear sleeve are removed a new seal and wear sleeve must be installed.end by:a) install oil filter housingb) install crankcase breatherc) install front crankshaft seal and wear sleeved) install accessory drive (front)e) install governor drive