0388644 EVINRUDE WATER PUMP REPAIR KIT

Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 2
B 9U-6238 Guide Bolt 2
C 8T-3052 Degree Wheel 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Thoroughly clean the top of the cylinder block and the bottom of the cylinder head. Ensure that there is no debris in the cylinder bores.
Illustration 1 g00942889
Install cylinder head gasket (3) on dowels (4) on top of the cylinder block. The cylinder head gasket (3) is stamped "FRONT TOP". Do not use any sealant or compound on the cylinder head gasket.
Install Tooling (B) in the cylinder block in Hole (X).
Illustration 2 g00942891
Install Tooling (A) and a suitable lifting device to cylinder head (2). The weight of the cylinder head is approximately 61 kg (135 lb).
Install cylinder head (2) on the cylinder block. Note: Ensure that the cylinder head is positioned on dowels (4).
Remove Tooling (A). Remove the guide bolts.
Illustration 3 g00942928
Clean the threads of the cylinder head bolts. Inspect the cylinder head bolts. Note: Do Not use bolts if there is any visual reduction in the diameter of the Threads (Y) that has not been engaged with the cylinder block. Use a straight edge to check the bolts.
Lubricate the threads and the shoulder of the cylinder head bolts with clean engine oil before installation.
Install bolts (1) on cylinder head (2). Note: The short bolts are installed in holes that are marked with an "S" (5, 6, 11, 12, 16, 17, 21, 22, 26, 27, 31, and 32).Note: The medium bolts are installed in holes that are marked with an "M" (1, 2, 3, 4, 7, 8, 9, 10, 13, 14, 15, 18, 19, 20, 23, 25, 28, and 30).Note: The long bolts are installed in holes that are marked with an "L" (24 and 29).
Illustration 4 g00893273
Tighten bolt (1) through bolt (32) in numerical order to a torque of 110 N m (80 lb ft). Refer to Illustration 4.
Tighten bolt (1) through bolt (32) again in numerical order to a torque of 110 N m (80 lb ft). Refer to Illustration 4.
Illustration 5 g00946758
Use Tooling (C) to achieve the correct final torque. Note: If Tooling (C) is not used, place an index mark on each bolt.
Tighten the cylinder head bolts in numerical order. Refer to Illustration 4.
Turn the bolts that are marked with an "S" an additional 150 degrees.
Turn the bolts that are marked with an "M" an additional 180 degrees.
Turn the bolts that are marked with an "L" an additional 210 degrees.
Connect the harness assembly for the coolant temperature sensor. End By:
Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install".
Install the water outlet manifold. Refer to Disassembly and Assembly, "Water Outlet Manifold - Install".
Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install".
Install the air inlet manifold. Refer to Disassembly and Assembly, "Inlet Manifold - Install".
Install the fuel injection nozzles. Refer to Disassembly and Assembly, "Fuel Injection Nozzles - Install".