5040174 EVINRUDE Pump Case Liner

1. Remove the carbon from the top inside surface of the cylinder liners.2. Turn the crankshaft until two pistons are at bottom center.3. Remove bearing caps (1) from the two connecting rods. Put pieces of rubber hose or tape on the threads of the connecting rod bolts as protection for the crankshaft. Put identification on each bearing cap so it will be installed on the correct connecting rod. 4. Push the pistons up until the piston rings are clear of the cylinder liner. Remove pistons (2).
Do not turn the crankshaft while any of the connecting rods are in the engine without the caps installed. Do not damage the piston cooling jets when the pistons are removed.
5. Repeat Steps 1 through 4 for the remainder of the pistons.Install Pistons & Connecting Rod Assemblies
1. Be sure that the pistons are installed with the flat surfaces (2) of the connecting rods toward each other and the chamfered sides (1) toward the crankshaft. 2. Put clean engine oil on the piston rings and cylinder liners.3. Put two pistons in position opposite of each other in the correct bore of the block. Install pistons (3) with Tool (A). For more detail about checking bearing clearances and installation of connecting rod bearings, see the topic, "Remove & Install Connecting Rod Bearings".4. Check the bearing clearances with Plastigage.5. Put clean engine oil on bolts (4). Install caps (5) and nuts finger tight. Make sure flat side (6) of each cap is toward the other cap. The chamfered side must be toward the crankshaft. Tighten each nut to a torque of 82 8 N m (60 6 lb ft). Put a mark across the nuts and bolts. Tighten each nut an additional 120 5 degrees.
Do not use an impact wrench to tighten the nuts the additional 120 degrees.
6. Check the side clearance between two connecting rods on the same crankshaft journal. Clearance must be 0.28 to 0.84 mm (.011 to .033 in) for new rods.7. Repeat Steps 1 through 6 for the remainder of the pistons. For more detailed information regarding the pistons and connecting rods, see the topic "Pistons & Rings" and the topic "Connecting Rods" in the Specifications Module.End By:a. install piston cooling jetsb. install engine oil pumpc. install cylinder headsDisassemble & Assemble Pistons & Connecting Rod Assemblies (One Piece Piston)
Start By:a. remove pistons and connecting rod assemblies 1. Remove bearings (3) from the connecting rod and connecting rod cap.2. Remove retainer ring (1) with Tool (A) (no special Tool necessary).3. Remove pin (2) and connecting rod (4) from the piston. 4. Remove piston rings (5) from the piston with Tool (B). Clean the piston ring grooves on the pistons with an acceptable ring groove cleaning tool. See the topic "Use Of Piston Pin Bearing Removal & Installation Tools" in Special Instructions, SMHS7295.5. Heat connecting rod (4) in an oven to a temperature of 177° to 260°C (350° to