0336880 EVINRUDE ROD, Grill

Start By:a. remove hood1. Remove the air conditioner condenser if so equipped. Prior to removing the condenser, the system must be purged. Refer to the Air Conditioning And Heating Service Manual, Form No. SENR3334-01 for purging the system.
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 cap is cool enought to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
2. Release the pressure in the cooling system by slowly loosening the filler cap on the radiator. Drain the coolant from the radiator into a suitable container for storage or disposal. The capacity of the cooling system is 49 liters (12.7 U.S. gal). 3. Remove sixteen bolts (1) and fan guards (2) from the machine. 4. Remove four bolts (4) and the washers. Remove enclosure top panel assembly (3). 5. Put identification marks on the two wires connected to the back-up alarm for installation purposes. Disconnect the wires from back-up alarm (5). 6. Fasten two lifting straps and a hoist to radiator grill assembly (6).7. Remove six bolts (7) and the washers that hold the radiator grill assembly in position. Remove the radiator grill assembly. The weight of the radiator grill assembly is 52 kg (115 lb). 8. Remove four screws (9) and the washers that hold plate (8). Remove the plate from the tail light. Remove plate (8) from the other tail light. 9. Put identification marks on two wires (10) for assembly purposes. Disconnect two wires (10) and one connector (11). Disconnect the two wires and one connector from the other tail light.
Do not damage the wiring harnesses for the tail lights during removal of the side panel assemblies for the radiator. The wiring harnesses should be slowly fed through the grommets in the side panel assemblies.
10. Fasten tool (A) and a hoist to radiator side panel assembly (12) as shown.11. Remove four bolts (13) and the washers from the rear of the enclosure and also from the engine side of the enclosure. Remove side panel assembly (12). The weight of the side panel assembly is 34 kg (75 lb).12. Remove side panel assembly (14) from the other side of the radiator as in Step 11. 13. Remove three bolts (16) and the washers that hold side latch bracket (15) in position. Remove the side latch bracket. Remove the side latch bracket on the other side of the radiator. 14. Loosen the clamps, and disconnect three hoses (19) from the radiator top tank assembly.15. Remove ten bolts (21) and the washers, and remove guard (20).16. Remove seventeen bolts (18) and the washers from radiator top tank assembly (17). 17. Remove four bolts (22) and the washers that hold hydraulic oil cooler cores (23) to radiator top tank (17) at the rear. Remove the four bolts and washers that hold the hydraulic oil cooler cores to the radiator top tank at the front. 18. Fasten tool (A) and a hoist to radiator top tank assembly (17) as shown. Remove the radiator top tank assembly and the gasket from the radiator cores and the hydraulic oil cooler cores. The weight of the radiator top tank assembly is 50 kg (110 lb). The radiator is made up of several individual cores. These cores can be removed separately for servicing. 19. Remove appropriate bolts (25), the washers and nuts that hold the cores together in the center.20. Remove radiator core (24) from the lower radiator tank assembly. The weight of a radiator core is 13 kg (29 lb).21. Remove the 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 23 kg (50 lb).22. Remove the end seals from radiator top tank assembly and the lower radiator tank assembly. The following steps are for the installation of the radiator.23. Fasten a hoist to the lower radiator tank assembly, and put it in its original position on the frame of the machine. Install the bolts and washers that hold it. 24. Check the condition of the end seals which are used in the lower radiator tank assembly and the radiator top tank assembly. If the seals are worn or damaged, use new parts for replacement. Install the end seals in the lower radiator tank assembly and the radiator top tank assembly.25. Put a thin coat of 5P3975 Rubber Lubricant on the center mounting tube of radiator core (24). Install the core in the lower radiator tank assembly.26. Install bolts (25) and the washers that hold the cores together in the center. 27. Fasten tool (A) and a hoist to radiator top tank assembly (17). Put a thin coat of 5P3975 Rubber Lubricant on the center mounting tube of each core. Put the radiator top tank assembly and the gasket in position on the radiator cores and the hydraulic oil cooler cores. 28. Install eight bolts (22) and the washers that hold hydraulic oil cooler cores (23) to the radiator top tank assembly. Four bolts are located at the rear of the radiator top tank assembly, and four bolts are located in front of the radiator top tank assembly. 29. Install seventeen bolts (18) and the washers in the radiator top tank assembly.30. Put guards (20) in position, and install the washers and ten bolts (21) that hold the guards.31. Connect three hoses (19) to the radiator top tank assembly. 32. Reinstall a side latch brackets (15) on each side of the radiator.
Do not damage the wiring harnesses for the tail lights during installation of the side panel assemblies for the radiator. The wiring harnesses should be slowly fed through the grommets in the side panel assemblies.
33. Fasten tool (A) and a hoist