5041221 EVINRUDE WATER PIPE SEAL (UPPER)

3. Remove two fuel lines (1) from the fuel filter to the fuel transfer pump. The oil cooler can be removed without removing fuel lines (1). It is much more difficult however, and there is the possibility of damage to the fuel lines during final removal and installation. 4. Remove two bolts (2), adapter and pipe (3). Weight of adapter and pipe is 9 kg (22 lb). 5. Attach straps and hoist to the oil cooler and remove two bolts (4). 6. Remove two bolts (5) from front under portion of oil cooler. These two bolts are located directly above the fuel transfer pump. 7. Slowly hoist the oil cooler away from the engine. It will separate at point (A) and (B). Both points have slip fit O-ring connections. Weight of the oil cooler is 84 kg (185 lb). Installation of the oil cooler is accomplished in the exact reverse order from removal. Prior to installation, lubricate the slip fit O-ring seals on the ends of pipe (3) and the oil cooler with clean oil to insure proper installation. Replace the gasket on the opposite end of pipe (3). Check the oil level, and replace any oil that has been lost during removal with clean oil. Refill the cooling system with fluid. See the Maintenance Manual for correct fluid levels.End By:a. install fuel filter housingDisassemble Oil Cooler
Start By:a. remove oil cooler 1. Remove the bolts from elbow (1), and remove elbow (1) and tube (2) as a unit from the oil cooler. 2. Remove tube (2) from elbow (1), and remove the O-ring seals from tube (2) and elbow (1). 3. Put alignment marks on bonnet (3) and core assembly (4) for correct alignment at assembly. Remove bonnet (3) from core assembly (4). 4. Remove flange (7) and tube (6) as a unit from bonnet (5). Remove the O-ring seals from tube (6). 5. Remove the bolts, and remove elbow (8) from core assembly (4). 6. Remove the bolts, and remove cover (9) from elbow (8). Remove the O-ring seal from cover (9). 7. Remove spring (10) and plunger (11) from elbow (8). 8. Remove the bolts to remove cover (13), and remove O-ring seals (12) from elbow (8). 9. Put alignment marks on bonnet (5) and core assembly (4) for correct alignment at assembly. Remove bonnet (5) from core assembly (4).Assemble Oil Cooler
1. Make sure the tubes in core assembly (1) are clean and free of dirt and foreign material. 2. Put the gasket and bonnet (2) in position on core assembly (1), and install the bolts. 3. Install O-ring seals (4) on elbow (3), and put clean engine oil on the seals. Install cover (5) on elbow (3). 4. Put plunger (7) and spring (8) in position in elbow (3). Install the O-ring seal in cover (6), and put clean engine oil on it. Install cover (6) on elbow (3). 5. Put elbow (3) in position on the core assembly, and install the bolts. 6. Install the O-ring seals on tube (9), and put clean engine oil on the seals. Install tube (9) and flange (10) as a unit in bonnet (2). 7. Put the gasket and bonnet (11) in position on core assembly (1), and install the bolts. 8. Install the O-ring seals on tube (13), and put clean engine oil on the seals. Install tube (13) in elbow (12). 9. Install the O-ring seal on elbow (12), and put clean engine oil on it. Put elbow (12) and tube (13) as a unit in position, and install the bolts in elbow (12) to hold the elbow and the tube in position.End By:a. install oil cooler