0389549 EVINRUDE FUEL CONN., HOSE & PRIMER BULB AY.

2. Remove clamp (2) from water sleeves (1) in each cylinder head. Push the water sleeves into the timing gear cover with tool (A) and a screwdriver.3. Remove bolt (3) from the bracket on the dipstick tube. 4. Remove bolts (4) and stud (5) from the heads.
Make sure the fuel injection nozzles are removed before the cylinder heads are removed. The fuel injection nozzles go through the cylinder heads and the nozzle tips can be broken off if the nozzles are not removed from the heads.
5. Install tooling (B), and fasten a hoist. Remove bolts (7), cylinder head (6) and the gasket. The weight of the cylinder head is 54 kg (120 lb.).Install Cylinder Heads
1. Clean the contact surfaces of the cylinder head and cylinder block. Make sure the surfaces are clean and dry. Install a new cylinder head gasket. Clean the bore in the cylinder head for the water sleeves. Put oil on the seals on the water sleeves.2. Install tooling (A) in the cylinder head. Fasten a hoist, and put cylinder head (1) in position on the cylinder block. 3. Put engine oil on the bolt threads, and install the bolts that hold the cylinder head in place. Tighten the bolts in the cylinder head according to the following procedure:a. Tighten bolts 1 through 18 in number sequence to 80 14 N m (60 10 lb.ft.).b. Tighten bolts 1 through 18 in number sequence of 150 7 N m (110 5 lb.ft.).c. Again tighten bolts 1 through 18 in number sequence to 150 7 N m (110 5 lb.ft.)d. Torque for head bolts 19 through 22 (tighten in number sequence to) 43 7 N m (32 5 lb.ft.). 4. Install water sleeve (3) into the cylinder head with tool (B) and a screwdriver.5. Install bolt (4) which holds the dipstick tube to the cylinder head. 6. Install clamp (5) on the water sleeves.7. Fill the cooling system with coolant to the correct level.END BY:a. install fuel injection nozzlesb. install fuel injection linesc. install air inlet manifoldd. install exhaust manifoldDisassemble Cylinder Heads
START BY:a. remove cylinder heads 1. Fasten a hoist, and put the cylinder head in position on tool (A). Use adapter plates (1) from tooling (A) to hold the head in place. 2. Put the valve springs under compression with tool (C).3. Remove the locks from the valves.4. Remove tool (C), retainer, spring, washer and valve from the cylinder head. Put identification on the valve as to its location in the cylinder head. 5. Check the valve spring force with tool (B). For the correct spring force, see the subject Valves in Specifications.6. Do Steps 2 through 5 for the remainder of the valves. 7. Remove the valve seat inserts with tooling (D). The valve guides are part of the cylinder head. Measure the bore in each valve guide 19.0 mm (.75 in.) from the outside edge on both ends of each valve guide. The bore must be 9.512 0.013 mm (.3745 .0005 in.). The maximum permissible bore is 9.550 mm (.3760 in.). Valve guides worn more than the maximum specification can be made to the original size by knurling.Assemble Cylinder Heads
1. Clean and remove burrs and all foreign material from the valve seat bores.
Do not make the diameter of the extractor [part of tooling (A)] in valve seat insert larger when the insert is installed in the cylinder head.
2. Lower the temperature of the valve seat inserts, and install them with tooling (A).3. Grind the valve inserts according to the dimensions given in Specifications. 4. Put clean engine oil on the valve stem. Install the valve, washer (3), springs (2) and retainer (1) in the cylinder head. 5. Put the valve springs under compression with tool (C).6. Install the locks on the valve stem with tool (B).
Locks (4) can be thrown from the valve when tool (C) is released if not in their correct position. To prevent possible personal injury, release tool (C) slowly, and stay as far away as possible.
7. Remove tool (C), and hit the valve with a rubber hammer to be sure the locks are in their correct position.8. Do Steps 4 through 7 for the remainder of the valves.END BY:a. install cylinder heads