5007635 EVINRUDE CYLINDER / CRANKCASE Assy, 200 HP

1. Loosen the clamps on hose (3), remove nuts (2) and remove temperature regulator housing (1) and the gasket from the cylinder head. 2. Remove bolt (5) and the nut from the bracket.3. Remove bolts (6) and (7) that hold the fuel injection lines in position. Remove fuel injection lines (4) from the engine.
Put protection caps (5F2807) and plugs (2F2990) on the injection lines and pumps to keep dirt and foreign material out of the fuel system.
4. Disconnect air lines (8) and (9) from the cylinder head. 5. Remove two locks and bolts (10). Remove the dowel used for location of the rear of the camshafts and remove four bolts (12). Remove valve cover base (11) and the gasket from the cylinder head. 6. Remove bolts (14) that hold cylinder head (13) to the cylinder block. 7. Install four 3/8"-16 NC forged eyebolts in the cylinder head as shown. Fasten a hoist and remove the cylinder head. The weight of the cylinder head is 450 lb. (203 kg).8. Remove the water seals and the head gasket from the spacer plate. 9. Remove the O-ring seal from dowel (16).10. Install six 3/8"-16 NC forcing screws in spacer plate (15). Tighten the screws evenly until the spacer plate is free of the dowels. Remove spacer plate (15).11. Remove the second O-ring seal from dowel (16).Install Cylinder Head And Spacer Plate
A new spacer plate gasket must be installed when the cylinder head is removed.1. Thoroughly clean the top surface of the cylinder block, both surfaces of the spacer plate and the bottom surface of the cylinder head. 2. Put the O-ring seal in position around dowel (1).3. Put a new gasket in position on the cylinder block.
Both surfaces of the spacer plate and the top of the cylinder block must be clean. Do not use a gasket adhesive on these surfaces.
4. Install spacer plate (2) on the cylinder block. 5. Install the O-ring seal on the spacer plate around dowel (1).6. Check the cylinder liner projection. See INSTALL CYLINDER LINERS.7. Put a new cylinder head gasket and water seals in position on the spacer plate. 8. Install two 3/4"-10 NC guide bolts 11 in. long in the cylinder block. Install four 3/8"-16 NC forged eyebolts in the cylinder head. Fasten a hoist and put the cylinder head in position on the guide bolts and lower it on the engine. 9. Put 9M3710 Anti-Seize Compound on the threads of cylinder head bolts (3) and the washer faces. Install bolts (3), the washers and tighten as follows: a) Tighten the bolts in number sequence shown to a torque of 200 lb. ft. (270 N m).b) Tighten the bolts in number sequence shown to a torque of 330 10 lb. ft. (447 14 N m). c) Tighten the bolts in number sequence shown (hand tighten) to a torque of 330 10 lb. ft. (447 14 N m). 10. Put the gasket and valve cover base (4) in position on the cylinder head. Install the two bolts and locks that hold the valve cover base to the cylinder head. Install the bolts to hold the valve cover base to the timing gear plate.11. Install the dowels in the cylinder head that is used to locate the rear of the camshafts. 12. Connect air lines (5) and (6) to the cylinder head. 13. Remove all plugs and caps and put fuel injection lines (7) in position on the engine. Tighten the fuel injection line nuts to a torque of 30 5 lb. ft. (40 7 N m). 14. Install bolt (9) and the nut.15. Put the gasket and water temperature regulator housing (8) in position on the cylinder head and install the nuts that hold it. Tighten the clamps on hose (10).end by: a) install aftercoolerb) install exhaust manifoldc) install camshafts