0389038 EVINRUDE GEARCASE ASSY, Complete

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     4C-5592     Anti-Seize Compound     -    
B     8T-2998     Lubricant     -    
C     9S-3263     Thread Lock Compound     -    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01067188
Note: Thoroughly clean the spacer plate and the bottom surface of the cylinder head and the top of the cylinder block. A new spacer plate gasket and a cylinder head gasket must be installed when the cylinder head is removed.
Install O-ring seal (19) on the dowel in the cylinder block.
Install spacer plate gasket (21) on the cylinder block.
Install spacer plate (18) .
Install seals (22) and seal (20) .
Install cylinder head gasket (17) and the O-ring seal on the spacer plate.
Install a second O-ring seal (19) on the dowel.
Illustration 2 g01067444
Attach a suitable lifting device to cylinder head (16) . The weight of cylinder head (16) is approximately 235 kg (518 lb).
Carefully install the cylinder head on the dowel pins on the cylinder block.
Apply Tooling (A) to the threads of the cylinder head bolts (15) and both sides of the washers. Install cylinder head bolts (15) .
Illustration 3 g01072801
Note: The bolts that are marked "x" are 216 mm (8.5 inch) long: 11, 12, 13, 14, 16, 18, 20, 22, 24 and 26. The rest of the bolts are 194 mm (7.6 inch) long.
Tighten the cylinder head bolts according to the following procedure.
In a numerical sequence, tighten Bolt (1) through Bolt (26) to a torque of 270 15 N m (200 11 lb ft).
In a numerical sequence, tighten Bolt (1) through Bolt (26) to a torque of 450 15 N m (330 11 lb ft).
In a numerical sequence, again tighten Bolt (1) through Bolt (26) to a torque of 450 15 N m (330 11 lb ft).
Illustration 4 g01081883
Connect tube assembly (8) .
Connect tube assembly (10) .
Connect hose assembly (9) .
Connect hose (13) .
Connect hose assembly (7) at the cylinder head. Install the bolt and the clip that secures the hose assembly to the front housing. Install the bolt and the clip that secures the hose assembly to the cylinder head.
Install bracket (11) .
Connect inlet air temperature sensor (14) .
Connect boost pressure sensor (12) .
Install the gasket and the air inlet elbow on the cylinder head.
Position the breather tube on the cylinder head and tighten the bolt to a torque of 10 3 N m (89 27 lb in).
Illustration 5 g01067192
Install O-ring seal (5) and O-ring seal (6) on sealing plate (3) . Lubricate O-ring seal (6) with a 50/50 mixture of Tooling (B) and clean engine oil.
Illustration 6 g01067193
Illustration 7 g01067195
Install adapter assembly (4) and sealing plate (3) . Ensure that the dowel in adapter assembly (4) engages the hole in the camshaft.Note: Ensure that the O-ring seal stays in the groove in sealing plate (3) .
Install thrust plate (1) . Apply Tooling (C) to bolts (2) . Hold the thrust plate in position and install bolts (2) . Evenly tighten bolts (2) until sealing plate (3) and the O-ring seal are seated against the cylinder head.End By:
Install the water temperature regulator. Refer to Disassembly and Assembly, "Water Temperature Regulator - Remove and Install".
Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".
Install the valve mechanism cover base. Refer to Disassembly and Assembly, "Valve Mechanism Cover Base - Remove and Install".
Install the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Install".
Install the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Install".