0378138 EVINRUDE ROD, Thrust and retainer

Start By:a. remove valve cover basesb. remove spark plug adaptersc. remove exhaust manifold 1. Remove two clamps (4) and tube joint assembly (3).2. Remove two bolts and washers (1).3. Remove tube assembly (5) and two adapters (2). 4. Remove two bolts and washers (9).5. Remove tube assembly (7) and the adapter. Check the O-ring seal and the gasket for damage or wear. Replace with new parts if necessary.6. Remove three bolts (8).7. Remove regulator housing (6). Check the gasket for damage or wear. Replace with a new part if necessary. 8. Disconnect hose assembly (11) from cylinder head assembly (13). Cap and plug all openings immediately.9. Remove bolts and washers (12). Remove lifting bracket (14).10. Install Tooling (A) and a suitable lifting device to the cylinder head assembly as shown.11. Remove cylinder head assembly bolts (10).12. Remove cylinder head assembly (13). The weight of the cylinder head assembly is approximately 125 kg (275 lb) for the 3408 Engine and 135 kg (300 lb) for the 3412 Engine. 13. Remove cylinder head gasket (15). 14. Remove spacer plate (16) and the water ferrules. 15. Remove spacer plate gasket (17). A new spacer plate gasket must always be installed when the cylinder head assembly is removed.Install Cylinder Head Assembly
1. Thoroughly clean the spacer plate and bottom surface of the cylinder head assembly. Install spacer plate gasket (1). 2. Install spacer plate (2) and the water ferrules. 3. Install a new cylinder head gasket (3). 4. Fasten Tooling (A) and a suitable lifting device to cylinder head assembly (7). Make sure the cylinder head gasket is in its proper position and install the cylinder head assembly. Do not install the 3/8 ( in) Bolts along the top of the cylinder head assembly at this time.5. Use the tightening sequence below to tighten the bolts that hold the 3412 Engine cylinder head assembly in position.
Large bolts (3/4 inch). Put engine oil on the bolt threads and between the washers and the underside of the bolt heads.
(2) Small bolts (3/8 inch). See Step 5g.a. Tighten bolts 1 through 14 in number sequence to 270 25 N m (200 20 lb ft).b. Tighten bolts 1 through 14 in number sequence to 470 20 N m (345 15 lb ft).c. Tighten bolts 1 through 14 in number sequence again to 470 20 N m (345 15 lb ft).d. Tighten bolts 15 through 26 in number sequence to 270 25 N m (200 20 lb ft).e. Tighten bolts 15 through 26 in number sequence to 450 20 N m (330 15 lb ft).f. Tighten bolts 15 through 26 in number sequence again to 450 20 N m (330 15 lb ft).g. Install and tighten the 3/8 ( in Bolts) to 45 7 N m (33 5 lb ft).6. Use the tightening sequence below to tighten the bolts that hold the 3408 Engine cylinder head assembly in position.
Put 6V-4876 Molycoat Paste Lubricant on the bolt threads and between the washers and the underside of the bolt heads.a. Tighten bolts 1 through 14 in number sequence to 270 25 N m (200 20 lb ft).b. Tighten bolts 1 through 14 in number sequence to 470 20 N m (345 15 lb ft).c. Do Step b again.d. Tighten bolts 15 through 18 in number sequence again to 270 20 N m (200 20 lb ft).e. Tighten bolts 15 through 18 in number sequence to 450 20 N m (330 15 lb ft).f. Do Step e again.7. Install lifting bracket (6) and secure with four bolts and washers (5).8. Connect hose assembly (4). 9. Install regulator housing (8) in its original location and secure with three bolts (10).10. Install tube assembly (9) and the adapter. Secure with two bolts and washers (11). 11. Install two adapters (13), tube assembly (16) and secure with two bolts and washers (12).12. Install tube joint assembly (14) and two clamps (15).End By:a. install exhaust manifoldb. install spark plug adaptersc. install valve cover bases