0435819 EVINRUDE ENGINE COVER ASSY.

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Personal injury can result from hot oil or hot components.At operating temperature, oil is hot and under pressure. Hot oil can cause burns.Remove the fill cap only when the engine is stopped, and the fill cap is cool enough to touch with your bare hand.Do not allow hot oil or components to contact skin.
Personal injury can result from hot coolant, steam and alkali.At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand.Cooling System Conditioner contains alkali. Avoid contact with skin and eyes.
Position a suitable container under the radiator drain valves in order to contain the coolant for storage or disposal. Drain 132 L (35 US gal) of coolant from the radiator. Refer to Operation and Maintenance Manual, SEBU7173, "Cooling System Coolant (ELC) - Change" for the correct procedure.
Install caps and plugs on all openings in order to prevent dirt or debris from entering the system. Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.
Raise the front hood assembly and the rear hood assembly.
Drain the coolant from the cooling system until the level is below the turbochargers.
Illustration 1 g00573358
Loosen clamp (1) in order to disconnect elbow (2) from the turbocharger.
Illustration 2 g00573359
Disconnect tube assembly (3) from the union tee.
Illustration 3 g00573360
Remove tube assembly (4).
Illustration 4 g00573361
Disconnect hose assembly (5).
Illustration 5 g00573362
Remove two bolts (6) and the washers that hold adapter (8) to cartridge (9). Remove bracket (7), adapter (8) and the gasket from cartridge (9).
Illustration 6 g00573363
Disconnect elbow (10) and the gasket (not shown) by removing two bolts (11) and the washers.
Illustration 7 g00573364
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Remove two bolts (12), the retainers and the washers in order to disconnect turbocharger (13) and the O-ring seals from the air inlet elbow.
Remove four nuts (14), four bolts (15) and the gasket (not shown) in order to disconnect turbocharger (13) from the engine. Discard nuts (14), bolts (15) and the gasket after removal. Do not use these components for the installation of the turbocharger.
Illustration 9 g00573367
Illustration 10 g00573611
Loosen clamp (16) in order to disconnect turbocharger (13) from the exhaust pipe support.
Remove two bolts (17), the washers and elbow (18) from the turbocharger.
Position a suitable lifting sling around turbocharger (13). Secure the lifting sling to a hoist. Remove turbocharger (13) from the engine. The weight of turbocharger (13) is 29 kg (64 lb).
Repeat this procedure for the remaining turbocharger on the opposite si