0338118 EVINRUDE HOUSING

At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water or steam. Any contact can cause severe burns. Look at the sight gauge to check the coolant level. The coolant level should be in the green range. If necessary, remove the fill cap only after the engine has been stopped and the cap is cool enough to remove with your bare hand. Remove the cooling system fill cap slowly to relieve pressure. Cooling system condition contains alkali that can cause personal injury. Avoid contact with the skin and eyes and do not drink. Allow cooling system components to cool before draining.
1. Drain the coolant from the cooling system into a suitable container for storage or disposal. There is approximately 106 L (28 gal U.S.) coolant in the machine. 2. Remove the bolts and remove ladder assembly (1). The weight of the ladder assembly is approximately 20.4 kg (45 lb). 3. Fasten Tool (A) and a hoist to the cowl assembly. Remove bolts (2). Remove cowl assembly (3) and guard assembly from the radiator as a unit. The weight of the cowl assembly and guard assembly combined is approximately 72.6 kg (160 lb). 4. Disconnect hose assemblies (4) and (5) from the air conditioning condenser. 5. Remove wiring harness (6) and electrical cable (7) from the top of the radiator. 6. Disconnect clips (8) from the radiator shield assembly. Pull hoses (9) clear of the radiator.7. Disconnect the wiring harness from the right headlight. 8. Disconnect and plug hose assembly (10) from the elbow.
View from under the machine9. Loosen lower clamp (11) from the radiator hose. Remove bolts (12) and remove elbow (13), the hose, and the tube from the radiator hose and the bottom of the radiator. 10. Remove bolts (14) and remove guard (15) in front of the radiator. 11. Remove bolts (16), the washers and spacers from the lower clamp assemblies on each side of the radiator. 12. Loosen clamps (17). Remove bolts (18). Remove tube assemblies (19) from the rear of the radiator. 13. Remove bolts (20) that secure the fan guards to the shield assembly. 14. Fasten Tool (A) and a hoist to the top of the radiator. Remove bolts (21). Remove caps (22) from each side of the radiator.15. Use the hoist to lift the radiator approximately 50.8 mm (2 in). Remove supports (23) from each side of the radiator. 16. Remove radiator (24) from the machine. The weight of the radiator is approximately 450 kg (1000 lb).Install Radiator Group
Check the condition of the radiator prior to installation. Remove any dirt or debris that may restrict the flow of air through the core. If any of the cooling fins are bent, they should be straightened prior to installation. 1. Fasten Tool (A) and a hoist to the radiator. Place radiator (24) in position in the machine. 2. Place supports (23) in position on each side of the frame. Install the bolts that secure the supports. Place the weight of the radiator on the supports.3. Place caps (22) in position on each side of the radiator. Install bolts (21) that secure the caps. 4. Use bolts (20) to secure fan guards to the shield assembly. 5. Install new gaskets on the tube assemblies. Place tube assemblies (19) in position in the hoses and on the rear of the radiator. Install bolts (18) that secure the tube assemblies. Tighten clamps (17) to a torque of 14.5 2 N m (128.50 17.70 lb in). 6. Install spacers, washers and the bolts to the lower clamp assemblies on each side of the radiator. 7. Using three bolts (14) install guard (15) in the front of the radiator.
View from under machine8. Using bolts (12) install elbow (13), the hose, and the tube to the radiator hose and the bottom of the radiator. 9. Connect hose assembly (10) at the elbow. 10. Connect the wiring harness to the right headlight.11. Using clips (8), route and secure hoses (9) to the radiator shield assembly. 12. Route and secure wiring harness (6) and electrical cable (7) along the top of the radiator. 13. Connect hose assemblies (5) and (4) to the air conditioning condenser. 14. Fasten Tool (A) and a hoist to the cowl assembly. Place cowl assembly (3) and guard assembly in position on the machine as a unit. Install bolts (2) that secure the cowl and guard assembly. 15. Install ladder assembly (1).16. Fill the cooling system with coolant to the correct level. Refer to the Operation & Maintenance Manual SEBU6968 for the correct capacity and fluid.End By:a. install crankcase guardsb. install air conditioner accumulatorc. install hood (front hood assembly only)