5040008 EVINRUDE Pin 3.5-28

Start By:a. remove turbochargerb. remove rear crankshaft seal and wear sleevec. remove engine oil pan 1. Remove exhaust clamp (1). 2. Remove exhaust clamp (2). 3. Remove bolts (6), cover (3), bolts (7), cover (4), bolts (8), cover (5) and the gaskets. 4. Remove bolts (9). 5. Install Tool (A), attach chains and a suitable lifting device toadapter assembly (11).6. Use the correct size forcing screws (10) to separate adapter assembly (11) from the flywheel housing. The weight of the adapter assembly is 31 kg (68 lb).7. Remove four bolts (12) and washer (13). 8. Place adapter assembly (11) in position as shown and press gear assembly (14) out of the adapter assembly. 9. Use Tool (B) to remove bearing (15) from the gear. 10. Use a press to remove bearing (16) from adapter assembly (11). 11. Remove six bolts (17) and ring (18) from adapter assembly (11).12. Remove O-ring seal (19) from adapter assembly (11). 13. If necessary remove race (20) from adapter assembly (11). 14. Remove two nuts (21) and the washers.15. Remove adapter assembly (22). 16. Remove O-ring seal (23) from adapter assembly (22). 17. Remove pin (27), bolts (25), washer (24) and gear (26) from adapter assembly (22). 18. Remove bolts (28) from adapter assembly (29). 19. Install Tool (A), attach chains and a suitable lifting device to adapter assembly (29).20. Use the correct size forcing screws (10) to remove adapter assembly (29). 21. Install Tool (C), attach chains and a suitable lifting device to flywheel housing (30).22. Remove hose assembly (31). Remove twenty-one bolts (32) and the washers.23. Remove flywheel housing (30) and the gasket. The weight of the flywheel housing is approximately 91 kg (200 lb). 24. If necessary remove sleeve (33). 25. With the flywheel housing in the position shown, remove bolts (34) from shafts (35).
The bearing toward the flywheel housing will fall when the gears are removed. Hold these bearings in position when the gears are removed.
26. Remove balancer gear (37) and idler gear (36). 27. Disassemble balancer gear assembly (37) as follows: a. Remove shaft (38), spacer (40), bearings (39) and (41) from the balancer gear.b. Remove bearing cups (42) and (45). Remove spacer (43) from gear (37). The bearing cups will have damage after removal. Use new parts for replacement.c. If necessary remove ring (44) from gear (37).28. Disassemble idler gear (36) the same as in Steps 27a through 27c. 29. Install guide bolts (D) and remove gear (46) from the crankshaft.30. Remove the O-ring seal from gear (46). 31. Remove four bolts (47) and remove camshaft gear (48). 32. If necessary, remove dowel (49).Install Flywheel Housing & Rear Gear Group
If the O-ring seals or gaskets are worn or damaged, replace them with new parts. 1. Install dowel (1) in the camshaft if it was removed. 2. Put camshaft gear (3) in position on the camshaft and install four bolts (2). 3. Install the O-ring seal on gear (4).4. Put clean engine oil on the seal and on the end of the crankshaft.5. Install Tool (A) in the crankshaft and install gear (4). 6. Assemble balancer gear (7) as follows: a. Install ring (5) in gear (7).b. Install spacer (6) in gear (7) in the timing mark side of the gear, as shown.c. Use a press and Tool (B) to install the bearing cones until they are in contact with the spacer. Install the bearing cone in the timing mark side of gear (7) first to hold the spacer in position. d. Install bearing (11), spacer (10), bearing (9), and shaft (8) into gear (7).7. Assemble idler gear (13) the same as in Steps 6a through 6d. 8. Put idler gear (13) and balancer gear (7) in position on the flywheel housing. Make sure the oil holes in shafts (8) align with the oil holes in the flywheel housing. Install balancer gear (7) with the timing mark toward the flywheel housing.9. Install bolts (12) to hold the balancer and idler gears on the flywheel housing. 10. If sleeve (14) was removed in the removal procedure, install a new sleeve. 11. Install a new gasket on the cylinder block.12. Attach Tool (C), chains, and a suitable lifting device to flywheel housing (15). The weight of the flywheel housing is approximately 91 kg (200 lbs). The front face of the flywheel housing, both sides of the flywheel housing gasket, and the rear face of the block must be free of oil, fuel, water, gasket adhesive, assembly compound, and any other contaminant during assembly.13. Remove plug (17).14. Put flywheel housing (15) in position and use hole (19) to visually align the "V" marks on the balancer gear and the crankshaft rear gear while the number one cylinder is at top center.15. Install twenty one bolts (18) and the washers.16. Install hose assembly (16).17. Install plug (17) with RTV Silicone red sealant.
Numerical Sequence18. Tighten bolts (1) through (21) in numerical sequence to 40 10 N m (30 7 lb ft). Tighten bolts 1 through 8 again in numerical sequence to a torque of 135 20 N m (100 lb ft) and bolts 9 through 21 in numerical sequence to a torque of 55 10 N m (41 lb ft). 19. Assemble adapter assembly (21) as follows: a. If the race was removed, install race (20) in adapter assembly (21) until the race makes contact with the counterbore. b. Install ring (23), bolts (22), and O-ring seal (24) on adapter assembly (21). c. Heat bearing (25) to 135°C (275°F) for approximately 30 minutes.d. Put bearing (25) on gear (26) until the bearing makes contact with the counterbore. e. Install gear (26) and the bearing in adapter assembly (21). f. Use a press and Tool (D) to install bearing (27) in adapter assembly (21). Install the bearing in the adapter assembly until it makes contact with the counterbore. 20. Install Tool (E), attach chains and a suitable lifting device to adapter assembly