5040113 EVINRUDE MAIN SWITCH ASSEMBLY

START BY:a. remove rocker shaft assembly and push rodsb. remove exhaust manifoldc. remove air cleaner groupd. remove aftercooler The procedure which follows was done on a 3306 Engine. 1. Remove bolts (1), mounting bracket and pipe assembly (2) and lifting bracket (3) from the cylinder head assembly. 2. Remove temperature sending unit (5) from elbow (4).3. Loosen clamp (6), and remove the bolts that hold elbow (4) to the water pump and cylinder head assembly. Remove the elbow and gaskets from the engine. 4. Install tooling (A) on the cylinder head assembly as shown, and fasten a hoist on it.
Do not set the cylinder head assembly on a flat surface because of possible damage to the fuel injection nozzle tips.
5. Remove all bolts (7) and (8) that hold the cylinder head assembly to the cylinder block. Remove the cylinder head assembly. The weight of the cylinder head assembly (3304) is 64 kg (142 lb.). The weight of the cylinder head assembly (3306) is 95 kg (210 lb.). 6. Remove head gasket (9), water seals (11) and the O-ring seal from dowel (10). Remove spacer plate (12), the spacer plate gasket and the O-ring seal from dowel (10).Install Cylinder Head Assembly And Spacer Plate
The procedure which follows was done on a 3306 Engine.
When the cylinder head assembly is removed a new spacer plate gasket and a new cylinder head gasket must be installed. Do not use any adhesive or other substances on these gaskets or the surfaces they contact.
1. Thoroughly clean the spacer plate, cylinder head and cylinder block surfaces. If dowel (1) was removed for any reason, install a new dowel until it extends 16.0 0.5 mm (.63 .02 in.) from the cylinder block.2. Install the O-ring seal on dowel (1) against the cylinder block. Install spacer plate gasket (2) and spacer plate (3) on the cylinder block.3. Check the cylinder liner projection height. See Install Cylinder Liners. 4. Install the O-ring seal on top of the spacer plate around dowel (1). Install cylinder head gasket (4) and water seals (5). 5. Install tooling (A) on the cylinder head assembly as shown, and fasten a hoist to it. Put the cylinder head assembly in position on the engine.6. Put 2P2506 Thread Lubricant on all the cylinder head bolts, and install them until they are finger tight. Remove tooling (A) from the engine. 7. Install push rods (6). Make sure they are installed in their original locations. Be sure the push rods are in position in the valve lifters.8. Loosen the adjusting screws on the rocker arms for valve clearance. This will prevent a bend valve or push rod during installation of the rocker shaft assembly.9. Install a new O-ring seal in the rear rocker arm support bracket.10. Put 2P2506 Thread Lubricant on all of the rocker shaft bolts except the one that goes through the rear rocker arm support bracket.11. Put rocker shaft assembly (7) in position on the cylinder head assembly. Make sure the dowels in the support brackets are in the dowel holes in the cylinder head assembly and the rocker arms are engaged with the push rods. Install the bolts that hold the rocker shaft assembly until they are finger tight.
3306 Engine Shown
3304 Engine Shown12. Hand tighten the large size cylinder head and rocker shaft bolts in the numbered sequence shown for each engine as follows:a. Tighten the bolts in the numbered sequence to a torque of 156 N m (115 lb.ft.).b. Tighten the bolts in the numbered sequence to a torque of 250 17 N m (185 13 lb.ft.).c. Tighten the bolts in the numbered sequence again to a torque of 250 17 N m (185 13 lb.ft.).13. Hand tighten the small size cylinder head bolts, in the lettered sequence shown for each engine to a torque of 43 7 N m (32 5 lb.ft.).14. See Valve Clearance in Testing And Adjusting, and make an adjustment to the valves. The intake valves must have a clearance of 0.38 mm (.015 in.). The exhaust valves must have a clearance of 0.64 mm (.025 in.). 15. Remove bolt (11). Put lifting bracket (8) and mounting bracket and pipe assembly (9) in position, and install bolts (10). Install bolt (11), and tighten it to a torque of 43 7 N m (32 5 lb.ft.). 16. Put the gaskets and elbow (12) in position and install the bolts that hold them. Tighten the hose clamp on the back side of the elbow.17. Install temperature sending unit (13) in the elbow.END BY:a. install valve coverb. install exhaust manifoldc. install air cleaner groupd. install aftercooler