0340591 EVINRUDE APPLIQUE, Johnson, port & stbd.

Start By:a. remove hood
At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.
1. Release the pressure in the cooling system by slowly loosening the filler cap on the radiator. Drain the coolant from the radiator. The capacity of the cooling system is 44 liters (11.4 U.S. gal).
At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. Remove the filler cap on the hydraulic oil tank only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Make sure all hydraulic pressure is released before any fitting, hose or component loosened, tightened, removed or adjusted.
2. Release the pressure in the hydraulic system as follows:a. Install the anti-pivot link.b. Move the lift control lever to the "Float" position.c. Shut off the engine.d. Move the lift control lever to the "Hold" position.e. Carefully loosen the filler cap on the hydraulic oil tank to release the pressure in the system.f. Carefully loosen the plugs located at the rear of the tilt cylinder. When the oil from the loosened plugs stops running, tighten the two plugs. To release the pressure in the attachment cylinders, carefully loosen the two large plugs near located near the plugs located at the rear of the tilt cylinder. When the oil from the two plugs stops running, tighten the two plugs.g. Tighten the filler cap on the hydraulic oil tank. The system pressure has now been released.3. Drain the oil from the hydraulic system. The capacity of the hydraulic system is 140 liters (36.4 U.S. gal). 4. Fasten a lifting sling and a hoist to grill (2) as shown.5. Remove bolt (1) and the washer. Open the grill. Do not remove the hoist from the grill at this time. 6. Disengage rod assembly (4) through hole (3) in the lower channel for the radiator guard. Remove the grill (2) from the machine. The weight of the grill is 34 kg (75 lb). 7. Remove six bolts (5) and the washers that hold frame (6) in position. Remove the frame. 8. Remove six bolts (7) and the washers that hold cover assembly (8) in position. Using two persons, remove the cover assembly. The weight of the cover assembly is 23 kg (50 lb).
Typical Example9. Remove cover (10) from each tail light (9).
Typical Example10. Disconnect wires (11) and wiring harness (12) from each tail light. 11. Loosen the hose clamps, and remove tube assembly (13) and hose (13a) from the radiator top tank assembly. 12. Remove bolts (15) and the washers that hold upper and lower fan guards (14) in position. Remove the fan guards. 13. Remove eight bolts (16) and the washers (four on each side of the radiator guard) that hold the right and left panel assemblies of the radiator guard to the fan shroud. 14. Fasten a hoist to left hand panel assembly (17). Remove eight bolts (18) that hold the panel assembly in position. Remove the left hand panel assembly. Remove the right hand panel assembly the same way. The weight of each panel assembly is 50 kg (110 lb). 15. Remove clamp (19) and hose (20) from the radiator top tank assembly. One bolt (22) has to be removed from the bottom side of plate (21) behind the fan assembly.16. Remove twelve bolts (22) and the washers from the fan shroud. 17. Loosen the clamps, and remove two hoses (24) at the top of the hydraulic oil cooler cores.18. Remove twelve bolts (23) and the washers that hold the hydraulic oil cooler cores to the radiator top tank assembly. Six of the bolts are on the back side of the radiator top tank assembly. 19. Remove ten bolts (25) and the washers that hold the radiator top tank assembly in place. 20. Fasten tool (A) and a hoist to radiator top tank assembly (26) as shown. Remove the radiator top tank assembly. The weight of the radiator top tank assembly is 32 kg (70 lb). The hydraulic oil cooler is made up of three individual cores. The radiator is made up of six individual cores. These cores can be removed separately for servicing. 21. If the hydraulic oil coolers cores are to be removed, loosen the clamps, and remove two hoses (27). Remove twelve bolts (28) and the washers that hold the cooler cores to the lower radiator tank assembly. Six of the bolts are located on the back side of the lower radiator tank assembly. 22. Remove appropriate bolts (29), the washers and nuts that hold the cores together in the center. 23. Remove radiator cores (30) or hydraulic oil cooler cores (31) from the lower radiator tank assembly. The weight of a radiator core is 13 kg (29 lb). The weight of a hydraulic oil cooler core is 21 kg (46 lb).24. Remove the twelve bolts and washers that hold the lower radiator tank assembly to the frame of the machine. Fasten a hoist to the lower radiator tank assembly, and remove it from the machine. The weight of the lower radiator tank assembly is 24 kg (53 lb). 25. Remove end seals (32) from the radiator top tank assembly and the lower radiator tank assembly. The following steps are for the installation of the radiator and hydraulic oil cooler.26. Fasten a hoist to the lower radiator tank assembly, and put it in its original position on the frame of the machine. Install the twelve bolts and washers that hold it. 27. Check the condition of end seals (32) which are used in the radiator top tank assembly and the lower radiator tank assembly. If the seals are worn or damaged, use new parts