0391736 EVINRUDE EXTENSION KIT - 5" 5" LONGER PARTS

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     138-7575     Link Bracket     2    
8T-4189 Bolt     2    
8T-4121 Hard Washer     2    
B     -     Guide Bolt
(M12 x 1.75 by 100 mm)     2    
C     -     Straight Edge     1    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Thoroughly clean the mating surfaces of the cylinder head and the cylinder block. Ensure that there is no debris in the cylinder bores, the coolant passages, or the lubricant passages.
Inspect the mating surface of the cylinder head for distortion. Refer to Specifications, "Cylinder Head" for more information.
Illustration 1 g01352861
Inspect dowels (8) for damage. If necessary, replace the dowels in the cylinder block.
Install Tooling (B) to the cylinder block. Refer to Illustration 1.
Illustration 2 g01346658
Typical example
If necessary, install a new joint (9) , lifting bracket (10) and bolts (11) to cylinder head (6) . Tighten the bolts to a torque of 11 N m (97 lb in).
Illustration 3 g01346253
Align cylinder head gasket (7) with Tooling (B) and install the cylinder head gasket onto the cylinder block.Note: Ensure that the word UP on the cylinder head gasket is upward.
Use Tooling (A) and a suitable lifting device to lift cylinder head (6) . The weight of the cylinder head is approximately 34 kg (75 lb). Align cylinder head (6) with Tooling (B) and install the cylinder head to the cylinder block.Note: Ensure that the cylinder head is correctly seated on dowels (8) .
Remove Tooling (B) .
Illustration 4 g01346700
Clean cylinder head bolts (5) . Inspect the threads of the bolts. Use Tooling (C) in order to check the bolts. The bolts must be renewed if there is any visual reduction in the diameter over area (X) .
Lubricate the threads and the shoulder of cylinder head bolts (5) with clean engine oil before installation.
Install cylinder head bolts (5) to cylinder head (6) .
Illustration 5 g01001090
The cylinder head tightening sequence
Tighten cylinder head bolts (5) in numerical order to the sequence that is shown in Illustration 5. Tighten the cylinder head bolts to a torque of 118 5 N m (87 4 lb ft).
Illustration 6 g01362487
Typical example
If necessary, install water temperature regulator housing (1) . Refer to Disassembly and Assembly, "Water Temperature Regulator Housing - Remove and Install".
Connect hose (2) to water temperature regulator housing (1) .
If necessary, install inlet manifold (3) . Refer to Disassembly and Assembly, "Inlet Manifold - Remove and Install".
Install breather hose (4) .
Install the rocker shaft and pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install".
Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.End By:
Install the glow plugs. Refer to Disassembly and Assembly, "Glow Plugs - Remove and Install".
Install the fuel injectors. Refer to Disassembly and Assembly, "Fuel Injectors - Remove and Install".
Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install".