5040290 EVINRUDE TILT SWITCH COVER

1. Remove elbows (1). 2. Remove harness (2) and bleed line (3). 3. Remove valve cover base (4). 4. Remove magneto assembly (5) bracket. Remove bolts (6) and the ground wire. 5. Remove bolts (7) to remove lifting bracket (8). 6. Fasten tooling (A) and a hoist to the cylinder head. Remove the bolts that hold the cylinder head in position. Remove cylinder head (9). Weight is 125 kg (275 lb.). 7. Remove cylinder head gasket (10). 8. Remove spacer plate (11) and the water ferrules. 9. Remove spacer plate gasket (12). A new spacer plate gasket must always be installed when the cylinder head is removed.Install Cylinder Head
1. Thoroughly clean the spacer plate and bottom surface of the cylinder head. 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 hoist to the cylinder head. Make sure the cylinder head gasket is in its proper position. Put engine oil on the threads of all the cylinder head bolts.5. Install the bolts, but do not tighten them at this time. Do not install the 3/8" bolts along the top of the cylinder at this time.6. Use the tightening sequence below to tighten the bolts that hold the cylinder heads in position.
(3412 Engines)a. Tighten bolts 1 through 20 in number sequence to 270 27 N m (200 20 lb.ft.).b. Tighten bolts 1 through 20 in number sequence to 450 20 N m (330 15 lb.ft.).c. Tighten bolts 1 through 20 in number sequence to 450 20 N m (330 15 lb.ft.).d. Install rocker shaft assembly (4) on the cylinder head.e. Tighten bolts 21 through 26 in number sequence to 270 27 N m (200 20 lb.ft.).f. Tighten bolts 21 through 26 in number sequence to 450 20 N m (330 15 lb.ft.).g. Tighten bolts 21 through 26 in number sequence to 450 20 N m (330 15 lb.ft.).h. Install and tighten the 3/8" bolts to 43 7 N m (32 5 lb.ft.).
(3408 Engines)a. Tighten bolts 1 through 14 in number sequence to 270 27 N m (200 20 lb.ft.).b. Tighten bolts 1 through 14 in number sequence to 450 20 N m (330 15 lb.ft.).c. Tighten bolts 1 through 14 in number sequence to 450 20 N m (330 15 lb.ft.).d. Install rocker shaft assembly (4) on the cylinder head.e. Tighten bolts 15 through 18 in number sequence to 270 25 N m (200 20 lb.ft.).f. Tighten bolts 15 through 18 in number sequence to 450 20 N m (330 15 lb.ft.).g. Tighten bolts 15 through 18 in number sequence to 450 20 N m (330 15 lb.ft.).h. Install and tighten the 3/8" bolts to 43 7 N m (32 5 lb.ft.). 7. Install elbow (5) and lifting eye (6). 8. Install spark plug adapters (7). 9. Install valve bridges. Use tool (B) to install the push rods. Use the following procedure to adjust the bridges.a. Put clean SAE 40 engine oil in the lubrication passage of the bridge.b. Back off the adjusting screw. Press straight down on the top contact surface of the bridge with a force of 40 to 60 N (9 to 13 lb.).c. Turn the adjusting screw clockwise until the oil film in the lubrication passage of the valve bridge moves inward, indicating the adjusting screw has made contact with the valve stem.d. Turn the screw an additional 15° to 25° (1/3 of a flat on the hex nut), to equalizer clearance with the dowel.e. Hold the adjusting screw in this position, and tighten the locknut to a torque of 85 to 115 N m (65 to 85 lb.ft.). It will be necessary to turn the engine with tool (C) to install some of the push rods. If the camshaft is in a position such that the valve will be open when the push rod is installed, tool (B) will not be able to put the springs in compression enough to install the push rods.
(3408 Engines)
(3412 Engines)11. Install valve cover base (8). Install bolts (9) and tighten them in number sequence to a torque of 14 4 N m (10 3 lb.ft.). 12. Install bleed line (10).End By:a. install exhaust manifold