5040672 EVINRUDE IDLE EXHAUST PORT GASKET

1. Remove the piston from the cylinder liner that is to be removed. See the topic "Remove Pistons" in this module.2. Turn the crankshaft so that the counterweights on the crankshaft are away from the bottom of the cylinder liner as shown. 3. Install Tool (A). Use Tool (A) to remove cylinder liner (1) from the block. 4. Remove filler band (2) and O-ring seals (3) from the cylinder liner.5. Do Steps 1 through 4 for the other cylinder liners if necessary.Install Cylinder Liners
1. Install clean liners or cylinder packs (1) in the engine block, (without the filler band or the rubber seals).2. Install the spacer plate gasket and the spacer plate. 3. Install Tool (A) around the cylinder liner as shown. Tighten the six bolts from Tool (A) evenly in four steps to a torque of 95 N m (70 lb ft).4. Use Tool (B) to measure the liner projection at positions indicated with A, B, C, and D in the illustration above. If the liner projection changes too much from point to point around the liner, turn the liner to a new position in the bore. If the projection measurements are still not within specifications, move the liner to a different bore in the cylinder block and check the projection again.5. If a liner does not measure within the correct projection specifications, the projection can be changed with a counterbore operation to the top surface of the cylinder block. The counterbore depth must be in a range from a minimum of 0.76 mm (.030 in.) to a maximum of 1.14 mm (.045 in). Shims are available to then adjust the liner to the correct projection. See Special Instruction, Form No. FMO55228-03, for procedure to use the 8S-3140 Cylinder Block Counter-boring Tool Arrangement. See the topic "Cylinder Liner Projection" in the Testing & Adjusting section of Service Manual to find shim thickness, part number and installation procedure.6. Put a mark on cylinder liner (1) and the spacer plate so the cylinder liner can be installed in the same position. Remove Tools (A) and (B). Remove cylinder liner (1).
Apply liquid soap and/or clean engine oil immediately before assembly. If applied too early, the O-rings seals and the filler bands may swell and be pinched under the liners during installation.
If the O-ring seals are black in color apply liquid soap on O-ring seals (3) and the bore of the cylinder block. Use clean engine oil on filler band (2). If the O-ring seals are brown, brown with blue coating or black with blue coating, apply clean engine oil on the O-ring seals, the bore of the cylinder block and the filler band.7. Install O-ring seals (3) and filler band (2) on the cylinder liner. Install the cylinder immediately into the cylinder block. 8. Use Tool (C) to install cylinder liner (1) in the block. Make sure the mark on the cylinder liner is in alignment with the mark on the spacer plate. For more information regarding installation of the cylinder liners see the topic "Cylinder Liner Projection" in Special Instruction Form No. SEHS9564-01.End By:a. install pistonsb. install spacer plate