0342028 EVINRUDE CAP, Check valve

start by:a) remove fuel injection linesb) remove water temperature regulatorc) remove exhaust manifoldd) remove rocket shaft and push rods1. Remove hood panels from above the engine. 2. Disconnect wires (1) from the water temperature switch. Put identification on the wires for assembly purposes.3. Remove water temperature switch (3).4. Loosen the clamp that holds the tube assembly to the radiator hose. Remove tube assembly (2). 5. Disconnect water line (5).6. Remove plate (4) from the cylinder head and front timing gear housing. 7. Disconnect filter indicator switch wire (6).8. Disconnect water temperature switch wire (7). Remove the clips that hold the wire to the back of the cylinder head and pull the wire clear of the cylinder head. 9. Disconnect air line (9) from the inlet manifold.10. Disconnect air line (10) from the fuel ratio control.11. Remove the bolts and remove inlet manifold (8) from the cylinder head. 12. Fasten a hoist to the cylinder head. Install tooling (A) as shown. Remove the bolts from the cylinder head. Remove cylinder head assembly (11). The weight of the cylinder head assembly is 425 lb. (191 kg).
Do not put the cylinder head down on a flat surface. This can cause damage to the fuel injection valves.
13. Put the cylinder head assembly on wood blocks as shown. Fasten a hoist to the air cleaner group. Remove air cleaner, pipe and support (12) from the cylinder head as a unit. The weight of the air cleaner group is 100 lb. (45 kg). Remove the rear lifting bracket.14. Remove muffler support (13) and front lifting bracket from the cylinder head. 15. Remove cylinder head gasket (15), O-ring seals (14) and twenty-four seals (16) from the spacer plate.Install Cylinder Head Assembly
Make sure a new gasket has been installed between the spacer plate and cylinder block. See REMOVE AND INSTALL SPACER PLATE. 1. Thoroughly clean the spacer plate and the bottom surface of the cylinder head. Install a new cylinder head gasket (3), seals (2) and O-ring seals (1). 2. Install lift brackets (5) and (6) on the cylinder head.3. Install muffler support (7).4. Fasten a hoist to the air cleaner group. Install air cleaner group (4) on the cylinder head. 5. Fasten a hoist to the cylinder head assembly. Install tooling (A) as shown. Put cylinder head assembly (8) in position on the engine. 6. Put clean SAE 30 oil on the threads of the cylinder head bolts. Install the cylinder head bolts. Tighten the bolts as follows: a) Tighten bolts 1 through 20 in number sequence to a torque of 200 20 lb.ft. (270 25 N m).b) Tighten bolts 1 through 20 in number sequence to a torque of 330 15 lb.ft. (447 20 N m).c) Tighten bolts 1 through 20 in number sequence to a torque of 330 15 lb.ft. (447 20 N m). 7. Put clean SAE 30 oil on the bridges. Install bridges (10) on the dowels.8. Install push rods (9). 9. Install rocker shafts (11). 10. Put clean SAE 30 oil on the threads of the rocker shaft bolts. Install the bolts in the rocker shafts. Tighten the bolts as follows: a) Tighten bolts 21 through 26 in number sequence to a torque of 200 20 lb.ft. (270 25 N m).b) Tighten bolts 21 through 26 in number sequence to a torque of 330 15 lb.ft. (447 20 N m).c) Tighten bolts 21 through 26 in number sequence to a torque of 330 15 lb.ft. (447 20 N m).11. Put clean SAE 30 oil on the threads of the 3/8" bolts. Install the twelve 3/8" bolts in the cylinder head. Tighten the bolts to a torque of 32 5 lb.ft. (43 7 N m). 12. Install inlet manifold (12) on the cylinder head. Connect the air line to inlet manifold. Connect the air line to the fuel ratio control. 13. Connect wire (13) to the water temperature switch.14. Connect the wire to the filter indicator switch.15. Install the plate on the cylinder head and front timing gear housing.16. Install the water temperature switch. Connect the wires to the switch. Connect the water line to the tee fitting in the cylinder head.17. Install the tube assembly in the radiator hose.18. Make an adjustment to the valves to have a clearance of .015 .003 in. (0.38 0.07 mm) for intake and .030 .003 in. (0.76 0.07 mm) for exhaust.19. Install hood panels above the engine. end by:a) install valve covers and basesb) install exhaust manifoldc) install water temperature regulatord) install fuel injection lines