Service Manual 115-200 HP E-TEC Powerhead [Powerhead Disassembly]

Fasten appropriate chain hook to eye of tool and support weight of powerhead with hoist.

Remove the four small powerhead screws, seven large powerhead screws, and the upper mount screws.

005273

1. Large powerhead screws
2. Small powerhead screws
3. Upper mount screws

Use a suitable tool to carefully separate the powerhead from exhaust housing.

005259

IMPORTANT: Do not damage the powerhead adapter mating surfaces when separating.

To simplify reassembly and wiring installation, lay out the various screws and clamps in the order of their proper location.

Remove the electric starter. Refer to Starter Removal on p. 168.

Remove fuel pump assemblies, fuel manifolds, and filter. Refer to FUEL COMPONENT SERVICING on p. 195.

Remove EMM and electrical harness with flywheel cover base, starter solenoid, and trim relay module. Refer to EMM SERVICING on p. 122.

Remove flywheel and stator. Refer to FLYWHEEL AND STATOR SERVICING on p. 162.

Remove oil pump, rear oil manifold, and oil circulation hoses. Refer to OIL COMPONENT SERVICING on p. 223.

Remove ignition coils and fuel injectors. Refer to Fuel Injector Service on p. 199.

IMPORTANT: Mark injectors for cylinder location before removal. All injectors must be installed in their original location. Improper injector installation can result in powerhead failure.

Remove throttle linkage. Refer to Throttle Linkage Removal on p. 243.

Remove shift linkage. Refer to Shift Linkage Removal on p. 243.

Remove the throttle body and reed plate assemblies. Refer to Intake Manifold Service on p. 201.

Remove pressure valve assembly. Refer to PRESSURE RELIEF VALVE SERVICING on p. 236.

Throttle Linkage Removal

Remove throttle cam and throttle lever.

005293

Shift Linkage Removal

Remove shoulder screw from shift arm and retaining screw from shift rod lever.

005294

1. Shift arm screw
2. Shift lever screw

Slide entire shift linkage assembly from crankcase.

Use a 1/8 in. diameter pin punch to push crankcase taper pin toward the front side of the engine.

IMPORTANT: Do not use a tapered punch or any other tool that could jam in or damage the taper bore when removing the pin.

005305

Remove crankcase flange screws.

005306

1. Flange screws (12 on V4; 16 on V6)

Loosen in stages and remove the main bearing screws.

005313

1. Main bearing screws (6 on V4; 8 on V6)

Separate crankcase and cylinder block. It may be necessary to tap on crankshaft with a rawhide or rubber mallet to loosen.

Carefully remove the crankcase from the cylinder block to avoid damaging the crankshaft seal rings.

Remove thermostat cover and thermostat assembly. Refer to THERMOSTAT SERVICING on p. 235.

Loosen in stages and remove cylinder head retaining screws. Remove the cylinder head.

Discard thermostat seal and O-rings.

005302

1. Cylinder head screws (28 on V4; 40 on V6)

Use a permanent marker to identify each connecting rod cap, connecting rod, and piston by cylinder number. Number 1 is closest to the flywheel.

005292

Use Torquing Socket, P/N 331638, to loosen in stages the rod cap retaining screws. DO NOT remove the screws.

005303

Use one hand to support the piston, and remove the rod cap screws with your other hand. Remove each piston and rod assembly.

005301

Reattach each rod cap to its rod as soon as the piston is removed. Each cap is unique and can only be installed on its mated rod. Do not allow rod to contact inside surface of cylinder or crankshaft.

IMPORTANT: Identify all internal components so that if reused, they can be reinstalled in their original positions.

Repeat steps for each remaining piston and connecting rod.

Use an appropriate ring expander to remove all piston rings from pistons. Discard the rings.

Wear safety glasses to avoid injury.

002054

Remove wrist pin retaining rings. Discard retaining rings.

46524

The wrist pin fit is loose on both sides. Push the wrist pin through to free the piston from the connecting rod. If necessary, use Wrist Pin Pressing Tool, P/N 326356, to remove the wrist pin bearing.

46520

Be careful not to lose any of the 28 needle bearings or the two wrist pin washers. If any of the bearings are worn or lost, replace all 28 bearings during reassembly.

Wear safety glasses to avoid injury.

Carefully lift crankshaft straight up and remove from crankcase.

005285

Remove upper seal from crankshaft. Discard the seal. A new upper seal must be installed on assembly.

49068

Remove the lower bearing seal housing.

005280

Remove the housing O-ring. Discard O-ring.

002044

Use a punch to remove the housing seal. Discard seal.

002053

1. Punch

Inspect housing and replace if necessary.

Remove O-ring from crankshaft sleeve and inspect it. Replace the O-ring if it is not in good condition.

29019

Inspect the crankshaft sleeve and replace if necessary. To remove the sleeve, use Slide Hammer, P/N 432128, and Large Puller Jaws, P/N 432129.

Remove the lower main bearing only if it needs to be replaced. Use external retaining ring pliers to remove the lower bearing retaining ring.

24384

IMPORTANT: If the lower main bearing is removed from the crankshaft, it must be discarded. DO NOT reuse it.

Use a bearing separator to support the bearing, and press off the crankshaft.

24383

Remove and inspect crankcase seal rings. Identify each ring for installation in original location.

49069

Remove center main bearings and split sleeves for inspection. Do not mix parts. Note location of bearings for reassembly.

24381