0397502 EVINRUDE BYPASS VALVE

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Guide Studs
M16 by 115mm 2
B 8T-3052 Degree Wheel 1
C 1U-6396 O-Ring Assembly Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the wiring harness assembly is correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness convoluting.
Thoroughly clean the gasket surfaces of the cylinder head and the cylinder block. Do not damage the gasket surfaces of the cylinder head of the cylinder block. Ensure that no debris enters the cylinder bores, the coolant passages, or the lubricant passages.
Inspect the gasket surface of the cylinder head for distortion. Refer to Specifications, "Cylinder Head" for more information. If the gasket surface of the cylinder head is distorted beyond maximum permitted limits, replace the cylinder head.
Illustration 1 g02460199
Inspect dowels (35) for damage. If necessary, replace the dowels in the cylinder block.
Install Tooling (A) to the cylinder block.
Align cylinder head gasket (36) with dowels (35). Install cylinder head gasket (36) onto the cylinder block.
Use a suitable lifting device to lift cylinder head. The weight of the cylinder head is approximately 66 kg (146 lb). Note: A spreader bar must be used in order to distribute the weight of the cylinder head during the lifting operation.
Use Tooling (A) to align the cylinder head with the cylinder block. Install the cylinder head to the cylinder block. Note: Ensure that the cylinder head is correctly positioned on dowels (35).
Remove Tooling (A).
Illustration 2 g02460202
Clean bolts (33). Follow Step 9.a for the procedure to inspect the bolts.
Use a straight edge to check the threads of the bolts. Refer to Illustration 2. Replace any bolts that show visual reduction in the diameter of the thread over Length (Y).
Lubricate the threads and the shoulder of bolts (33) with clean engine oil.
Illustration 3 g02452921
Illustration 4 g02460204
Install bolts (33) to cylinder head (34).
Tighten the bolts to a torque of 50 N m (37 lb ft) in the numerical sequence. Refer to Illustration 4.
Tighten the bolts to a torque of 100 N m (74 lb ft) in the numerical sequence. Refer to Illustration 4.
Use Tooling (B) in order to turn the bolts through an additional 225 degrees in the numerical sequence. Refer to Illustration 4.
Illustration 5 g02452920
Use Tooling (C) in order to lubricate the O-ring seals. Install new O-ring seal (31) and O-ring seal (32) to bypass tube (30). Install the bypass tube in the cylinder head. Install bolts (29). Tighten the bolts to a torque of 22 N m (195 lb in).
Follow Step 16.a through Step 16.d in order to connect harness assembly (26) to coolant temperature sensor (25).
Connect harness assembly (26) to coolant temperature sensor (25).
Slide locking tab (27) into the locked position.
Position harness assembly (26) onto bypass tube (30).
Install a new cable strap (28). Note: Ensure that the cable straps meet Original Equipment Manufactures (OEM) specification.
Illustration 6 g02456139
Position fuel filter bracket (19) onto the cylinder head.
Install bolts (23) to fuel filter bracket (19). Tighten the bolts to a torque of 22 N m (195 lb in).
Connect plastic tube assembly (18) plastic tube assembly (20) and plastic tube assembly (21) to clips (22) and clips (24).
Illustration 7 g02452919
Remove cap from tube assembly (15). Install a new O-ring seal (17) (not shown) to tube assembly (15).
Install tube assembly (15) to the bracket and the cylinder head.
Loosely install bolt (16) to tube assembly (15). Loosely tighten nut (12) on connection for tube assembly (15).
Tighten bolt (16) to a torque of 22 N m (195 lb in).
Use a suitable tool in order to hold tube assembly (15) in Position (X). Tighten nut (12) to a torque of 28 N m (248 lb in).
Install a new O-ring seal (14) (not shown). Connect hose assembly (13) to connection on tube assembly (15). Tighten Hose assembly securely.
Remove the plugs from plastic tube assembly (8) and plastic tube assembly (11). Remove caps from tube assemb