0435972 EVINRUDE ENGINE COVER ASSY., 200

Start By:a. remove radiator and guardb. remove air cleaner housingc. remove mufflerd. remove drive shafte. remove cabf. remove transmission guard. Prior to the disconnection or removal of any wires, wiring harnesses, hoses or cables insure that all are clearly marked and identified. For ease in removal of some bolts it may be desirable to remove the front belly guard. 1. Remove eight nuts (1), gasket (2) (not shown), and exhaust elbow (3) from exhaust manifold. Prior to the disconnection of any hose, line, wire, cable or wiring harness insure that both sides of the connection have been labeled for proper connection during installation.
Effective July 1, 1992 regulations prohibit the venting of any refrigerant into the atmosphere. Refer to Caterpillar publication SENR3334-01, SENR5664 and NEDG5065-01 for the proper procedure, equipment and tools to reclaim refrigerant from any Caterpillar machine.
Always wear goggles when working on air conditioning systems. The system is under pressure at all times, engine running or not. Escaping refrigerant R-12 (CC12F2 Dichloro Difluoro Methane) and refrigerant R-134A can cause freezing of human flesh. Do not smoke while working on air conditioning. Inhaling Refrigerant R-12 or R-134A through any smoking material, although not toxic or flammable, can cause violent illness. Also heat must never be applied to a charged system. See Air Conditioning And Heating Service Manual Form No. SENR3334-01 and SENR5664, for more information on removal and installation of lines and refrigerant from the system.
2. Using the proper reclaiming equipment, purge the air conditioning system. Mark and identify all wires and hose assemblies connected to the air conditioning compressor. Disconnect two wiring harnesses (4) and (5) at the quick disconnects and disconnect two hose assemblies (6) and (7). Remove bolt (8) and set hose assembly (6) aside. 4. Insure that the battery is disconnected. Remove tie straps around wiring harness located at the left front side of the firewall. Mark and identify all wires. Disconnect wiring harness (9), (10), (11), (12) and (13) at the quick disconnects. Follow wiring harness (14) through the firewall and disconnect wiring (14) at the quick disconnect (not shown) under the dash and carefully pull the wiring through the firewall. 5. Disconnect wiring harness (15) and ground cable (16) from the firewall. 6. Disconnect two wiring harnesses (17) and (18) at the quick disconnect located behind the right lift cylinder as shown. 7. Disconnect wiring assembly (19) from the alternator and remove all the tie straps that hold wiring assemblies (19) to the engine and set wiring assembly (19) to the side. 8. Remove bolt (20) holding clip and remove two bolts (21) and remove the air conditioning drier from the firewall with wiring harness and two hose assemblies still attached to the air conditioning drier. 9. Remove bolt and washer (22). Bolt (22) holds a clip on the inside of the firewall which holds a heater hose assembly. 10. Disconnect four rods (23), (24), (25), and (26). 11. Loosen two nuts (27), (28) and remove two cotter pins (29) and (30). Set aside decelerator cable assemblies (31) and governor cable assemblies (32). 12. Remove bolts, washers and nuts (33), on each side of firewall (34). 13. Attach tool (A) to firewall (34) as shown, slowly lift firewall (34) off machine. Weight of the firewall is 222 kg (490 lb). 14. Disconnect and plug heater hose (35). Remove bolt (36) and set heater hose aside. 15. Turn fuel shutoff valve OFF. Valve is located on the fuel tank. Disconnect and plug two fuel lines hoses (37), (38) and remove bolt (39). Set fuel line hoses (37), (38) aside. 16. Disconnect and plug heater hose (40) from engine and remove clip (not shown) holding heater hose (40) to tube assembly (41). 17. Remove two clips (42), (43) and disconnect tube assembly (41) at this end. 18. Disconnect two tube assemblies (41) and (44) from pump (45) and remove tube (41) only. 19. Remove three bolts, washers and spacers (46) and remove muffler support assembly. (47). 20. Remove two bolts (48) and set heater hose assembly (35) aside.21. Remove two bolts (49) and remove air conditioning hose assembly (6) from machine and disconnect wiring harness (50) at the quick disconnect.22. Remove four bolts, washers and shims (51) and remove plate assembly (52). 23. Disconnect hose assembly (53) from gear pump. 24. Disconnect two hose assemblies (54) and (55) at the control valves. 25. Remove four bolts (56) and set aside two transmission tubes (57) and (58) with seals (not shown) from the transmission case. 26. Remove tie strap (59) and disconnect cable assembly (60) from starter motor. 27. Remove two bolts, washers (61) and set bracket assembly (62) aside with cable assembly (60) still connected. Cable assembly will still be connected with a tie strap (not shown). 28. Disconnect two torque converter cooler hose assemblies (63) and (64) from the side of the transmission case. 29. Attach one end of tooling (B) to the front lifting eye of the engine. Attach the other end of tooling (B) to tooling (C) as shown. This positioning of tooling will prevent the engine and transmission from rotating and will allow ease of both removal and installation. 30. Remove two bolts, nuts, washers, sleeves and mount assemblies (65) from the engine. 31. Remove two bolts, nuts, washers, sleeves and mount assemblies (66) from the transmission support.32. Slowly lift engine and transmission out of the machine. The weight of the engine and transmission is 806 kg (1,775 lb). The following steps are necessary to install the engine.33. Check all O-rings, seals and hoses both on the engine and the transmission prior to installation and replace as necessary. 34. Slowly install the engine and transmission as a unit. Insure that no hoses or wiring harnesses are snagged during installation. 35. Install two bolts, nuts, washers, sleeves and mount assemblies (66) from t