0438049 EVINRUDE GEARCASE & BEARING ASSY.

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     6V-9120     Socket (1)     1    
B     8T-5096     Dial Indicator     1    
C     8T-9022     Silicone Gasket     1    
D     198-9113     Seal Installer     1    
( 1 ) Tooling (A) is a 46 mm socket.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01377349
Install thrust washer (14) on the rear face of the crankshaft with the oil groove toward the outside.
Position the upper halves of crankshaft main bearings (13) in the cylinder block. Install the bearings with the main bearing tabs in the correct position. Lubricate the bearings with clean engine oil.
Illustration 2 g01377339
Lubricate the crankshaft journals with clean engine oil. Attach a suitable lifting device to crankshaft (12). The weight of crankshaft (12) is approximately 40 kg (88 lb). Use the suitable lifting device in order to position crankshaft (12) onto the upper halves of the crankshaft main bearings.Note: Be careful not to damage the finished surfaces on the crankshaft.
Illustration 3 g01377519
This Illustration is of the rear main bearing cap.
Install main bearings (11) onto crankshaft main bearing caps (7) (not shown). Install main bearing (11) onto rear main bearing cap (8). Install bearings (11) with the main bearing tabs in the correct position. Lubricate main bearings (11) with clean engine oil.
Install thrust washers (10) onto rear main bearing cap (8). Make sure that the oil grooves on thrust washers (10) are facing away from rear main bearing cap (8) .
Illustration 4 g01377377
Illustration 5 g01385779
Apply Tooling (C) to the corners and the sides of rear main bearing cap (8). Install rear main bearing cap (8) to the cylinder block so that the rear face is even with the rear face of the cylinder block.
Apply soapy water to seals (9). Position seals (9) in the grooves on rear main bearing cap (8) with the rounded edges of seals (9) toward the outside. Use Tooling (D) in order to push seals (9) into position. This will reduce the risk of damaging the metal cores of seals (9). Apply Tooling (C) around seals (9). Cut off any excess length of seals (9) .
Illustration 6 g01385754
Install crankshaft main bearing caps (7). Put clean engine oil on the threads of new main bearing cap bolts (6). Install main bearing cap bolts (6). Tighten main bearing cap bolts (6) evenly to a torque of 137 5 N m (101 4 lb ft).Note: Ensure that crankshaft main bearing caps (7) are installed in the original locations.
Illustration 7 g01377571
Check the end play of the crankshaft with Tooling (B). The end play must be 0.100 to 0.264 mm (0.0039 to 0.0104 inch). Refer to the Specification, "Crankshaft" for more information on crankshaft end play.
Illustration 8 g01385745
Note: Remove tape or rubber tubing from the connecting rod bolts.
Apply a light coat of clean engine oil to the connecting rod bearing surfaces and to the connecting rod journals. Install the connecting rods onto the connecting rod journals.
Install the lower half of the connecting bearings into the corresponding connecting rod caps and install connecting rod caps (5) .Note: Align the tabs on the back of the connecting rod bearings with the tab grooves in connecting rod caps (5). Install new bolts (4) and the new nuts. Tighten bolts (4) to a torque of 103 5 N m (76 4 lb ft).
Install