0385502 EVINRUDE CRANKCASE HEAD ASSY

Note: Refer to Specification UENR3421 "Engine Design" for non-specified engine Torque Values.
Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining and filling procedures.
Illustration 1 g03339552
Illustration 2 g03339573
Gradually loosen cylinder head bolts (12) in reverse numerical order from (10) through (1) from cylinder head (11). Remove cylinder head bolts (12) from cylinder head (11) and discard.
Attach a suitable lifting device to cylinder head (11). The weight of cylinder head (11) is approximately 46 kg (100 lb).
Use the suitable lifting device to lift cylinder head (11) off the cylinder block.
Place the cylinder head on a surface that will not scratch the face of the cylinder head.
Illustration 3 g03339590
Remove cylinder head gasket (13) from the cylinder block.
Notice the location of the cylinder head gasket notches in area (A). Refer to Illustration 3 and Illustrations 4.
Note the position of the dowels in the cylinder block.
Illustration 4 g02796320
Notice the number of notches in Area (A).Installation Procedure
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Table 1
Head Gasket Notch Head Gasket Thickness Piston head protrusion or recessing from crankcase cylinder face
Before Tighten After Tighten
(a)-two notches 0.900 mm (0.0354 inch) 0.800 mm (0.0315 inch) 0.0775 to 0.150 mm (0.00306 to 0.00590 in.)
(b)-one notch 1.00 mm (0.039 inch) 0.900 mm (0.0354 inch) 0.150 to 0.250 mm (0.0059 to 0.0098 in.)
(c)-without notch 1.10 mm (0.043 inch) 1.00 mm (0.039 inch) 0.250 to 0.343 mm (0.0098 to 0.0135 in.)
Illustration 5 g02796320
Illustration 6 g03339590
Notice the number of notches in Area (A). Refer to Illustration 5 and Illustration 6.
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 dowels for damage. If necessary, replace the dowels in the cylinder block.
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.
Notice the location of the cylinder head gasket notches in area (A) and refer to Table 1. Align new cylinder head gasket (13) with the dowels.
Illustration 7 g03339552
Illustration 8 g03339573
Use a suitable lifting device to lift cylinder head (11). The weight of cylinder head (11) is approximately 46 kg (100 lb).
Align cylinder head (11) with the cylinder block. Install cylinder head (11) to the cylinder block.Note: Ensure that the cylinder head is correctly positioned on the dowels.
Lubricate the threads and the shoulder of new cylinder head bolts (12) with engine oil.
Install new cylinder head bolts (12) in numerical order from (1) through (10) to cylinder head (11).
Tighten the new cylinder head bolts according to the following procedure.
Tighten bolts (1) through (10) to a torque of 35 N m (26 lb ft)
Tighten bolts (1) through (10) to a torque of 108 N m (80 lb ft)
Tighten bolts (1) through (10) to a torque of 165 5 N m (122 4 lb ft)
Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct filling procedur