5040333 EVINRUDE SPRING

1. Remove support assembly (2) from the exhaust elbow and the air cleaners.2. Remove bolts (1) that hold the adapters to the turbochargers.3. Disconnect tubes (3) from the turbochargers. 4. Disconnect tube (4) from the fitting on the exhaust elbow.5. Remove the bolts that hold tube assemblies (5) to the adapter assembly.6. Disconnect tube (6) from the exhaust bypass. 7. Remove three bolts (7) that hold housing (8) to the engine. 8. Fasten a hoist and tooling (A) to exhaust elbow (9). Remove four bolts (10) that hold adapter assembly (11) to the engine. Remove exhaust elbow (9), adapter assembly (11) and the exhaust bypass as a unit from the engine. The weight of the unit is 49 Kg (108 lb.). 9. Remove adapter (12) and the coupling from both sides of exhaust elbow (9).10. Remove tubes (3) from adapter assembly (11).11. Remove housing (8) and the tube from adapter assembly (11). 12. Remove coupling (13) from adapter (12). 13. Remove seals (14) from coupling (13). 14. Remove four nuts (16), and remove exhaust bypass (15) from adapter assembly (11).15. Remove four nuts (17), and remove adapter assembly (11) from the exhaust elbow. The weight of the exhaust elbow is 29 Kg (64 lb.).
Exhaust bypass (15) is spring loaded. To prevent personal injury, loosen bolts (18) slowly and the same amount to remove the spring tension.
16. Remove bolts (18), and remove base assembly (19), gasket (20), spacers (21), inner spring (22), sleeve (23) and spring (24) from cover assembly (25).17. Remove breather assembly (26) from the cover assembly. 18. Remove nut (33), and remove valve (27), washer (28), plate (29), gasket (30), diaphragm (31) and retainer (32) from base assembly (19).Install Exhaust Elbow And Exhaust Bypass
1. Install valve (27), washer (28), plate (29), gasket (30), diaphragm (31) and retainer (32) in base assembly (19), and install nut (33). Tighten nut (33) to a torque of 12.5 1 N m (111 9 lb.in.). 2. Install breather assembly (26) on cover assembly (25).3. Position spring (24), sleeve (23), inner spring (22), spacers (21), gasket (20) and base assembly (19) on cover assembly (25).4. Install bolts (18) to hold the exhaust bypass together. Tighten bolts (18) to a torque of 6.5 1 N m (59 9 lb.in.). 5. Make sure the studs in the exhaust elbow are tightened to a torque of 30 5 N m (22 4 lb.ft.). Position adapter assembly (11) on the exhaust elbow. Apply 5P3931 Anti-Seize Compound on the threads of the studs in the exhaust elbow. Install four nuts (17) that hold the exhaust elbow and the adapter assembly together. Tighten nuts (17) to a torque of 30 5 N m (22 4 lb.ft.).6. Install exhaust bypass (15) in adapter assembly (11), and install four nuts (16) that hold it. 7. Install seals (14) in coupling (13). Make sure the breaks in the seal ring segments are installed approximately 45° apart ring to ring. 8. Install coupling (13) in adapter (12). 9. Put clean engine oil on the O-ring seals on the tube. Install the tube and housing (8) in adapter assembly (11).10. Put clean engine oil on the O-ring seals on tubes (3), and install tubes (3) in the adapter assembly.11. Install the coupling and adapter (12) in both sides of exhaust elbow (9). 12. Fasten a hoist and tooling (A) to the exhaust elbow and position the unit on the engine. Install four bolts (10) and the two clips that hold adapter assembly (11) to the engine. 13. With the gasket in place between the engine and housing (8), install bolts (7) that hold housing (8). 14. With the gaskets in place between the adapter assembly and tube assemblies (5), install the bolts that hold tube assemblies (5) in place.15. Connect tube (4) to the fitting on the exhaust elbow.16. Connect tube (6) to the fitting on the exhaust bypass. 17. Connect tubes (3) to the turbochargers.18. Install bolts (1) that hold the adapters to the turbochargers.19. Install support assembly (2) on the exhaust elbow and the air cleaners.