0436568 EVINRUDE ENG. COVER ASSY., Johnson

Start By:a. install body retaining pins Fluid Spillage ContainmentCare must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "Tools And Shop Product Guide, NENG2500", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.
At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water or steam. Any contact can cause severe burns. Look at the sight gage to check the coolant level. The coolant level should be in the green range. If necessary, remove the fill cap only after the engine has been stopped and the cap is cool enough to remove with your bare hand. Remove the cooling system fill cap slowly to relieve pressure. Cooling system condition contains alkali that can cause personal injury. Avoid contact with the skin and eyes and do not drink. Allow cooling system components to cool before draining.
1. Stop the engine, and allow the coolant to cool. Slowly loosen the filler cap to release the pressure from the cooling system. 2. Open front hood assembly (3). Remove four bolts (4) and the washers that hold front hood assembly (3) to the frame assembly. Remove cotter (1) and the washer that holds prop assembly (2) to front hood assembly (3). Close front hood assembly (3). 3. Remove ten bolts (6) and the washers that hold rail assembly (5) to front hood assembly (3). Put lifting slings in position around rail assembly (5). Attach the lifting slings to a suitable lifting device. Remove rail assembly (5) from front hood assembly (3). The weight of rail assembly (5) is 25 kg (55 lb).4. Remove five bolts (7) and the washers that hold front hood assembly (3) to cowling assembly (8). 5. Install Tooling (A) on front hood assembly (3). Attach Tooling (A) to a suitable lifting device. Remove front hood assembly (3). The weight of front hood assembly (3) is 62 kg (136 lb). 6. Mark the position of relief valve cover (10) for installation purposes. Remove five bolts (9) and the washers.7. Remove relief valve cover (10) from the radiator.8. Remove pressure relief valve (11) and two gaskets (12).9. Repeat steps 6 through 8 for the remaining pressure relief valve. The following steps are for the installation of the cooling system pressure relief valve. 10. Prior to installation, Clean all gasket material off the mating surfaces of the pressure relief valve. Check all parts for wear or damage and replace if necessary.11. Put a new gasket (12) in position on each side of pressure relief valve (11). Put pressure relief valve (11) in position in the radiator.12. Put relief valve cover (10) in position on the radiator, and install five bolts (9) and the washers.13. Repeat steps 6 through 8 for the remaining pressure relief valve. 14. Install Tooling (A) on front hood assembly (3). Attach Tooling (A) to a suitable lifting device. Put front hood assembly (3) in position on the frame assembly and the cowling assembly. 15. Install five bolts (7) and the washers that hold front hood assembly (3) to cowling assembly (8).16. Put lifting slings in position around rail assembly (5). Attach the lifting slings to a suitable lifting device. Put rail assembly (5) in position on front hood assembly (3). Install ten bolts (6) and the washers that hold rail assembly (5) to front hood assembly (3). 15. Open front hood assembly (3). Put prop assembly (2) in position on front hood assembly (3). Install the washer and cotter (1).16. Install four bolts (4) and the washers that hold front hood assembly (3) to the frame assembly.17. Check the engine cooling system level. Refill engine cooling system with coolant to the correct level. Refer to the Operation & Maintenance Manual for all fluid capacities and the proper filling procedures.End By:a. remove body retaining pins