Service Manual 5007213_Evinrude E-TEC 115-200 HP Powerhead [Disassembly]

Allen 1/4 in. hexagonal wrench. Attach suitable chain hoist to lifting tool.

With weight of power head supported by hoist, use a suitable tool to carefully separate the power head from exhaust housing.

IMPORTANT: Do not damage the power head adapter mating surfaces when separating. Remove the power head.

General

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. 161.

Remove fuel pump assemblies, fuel manifolds, and filter. Refer to FUEL COMPONENT SERVICING on p. 189.

Remove EMM , then remove electrical harness with flywheel cover base, starter solenoid, and trim relay module.

Remove flywheel and stator. Refer to FLYWHEEL AND STATOR SERVICING on p. 154.

Remove oil pump, rear oil manifold, and oil circulation hoses. Refer to OIL COMPONENT SERVICING on p. 222.

Remove ignition coils and fuel injectors. Refer to Fuel Injectors on p. 193.

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

Remove throttle cam screw and throttle lever screw.

1. Throttle cam screw
2. Throttle lever screw

Remove shoulder screw from shift arm and retaining screw from shift rod lever. Slide entire shift linkage assembly from crankcase.

1. Shift arm screw
2. Shift lever screw

Remove the throttle body and reed plate assemblies. Refer to INTAKE MANIFOLD on p. 196. Remove pressure valve assembly. Refer to PRESSURE RELIEF VALVE SERVICING on p. 233.

Remove crankcase flange screws.

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

Loosen in stages and remove the main bearing screws.

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

Using a 1/8 in. diameter pin punch, push crank case taper pin toward intake manifold side.

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

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.

Loosen in stages and remove cylinder head retaining screws. Remove the cylinder heads. Dis card thermostat seals.

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.

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

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

IMPORTANT: 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.

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Use Retaining Ring Pliers, or equivalent, to remove wrist pin retaining rings. Discard retaining rings.

Wear safety glasses to avoid injury.

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.

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.

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

If the lower crankshaft is to be resealed or the lower bearing replaced, remove the lower bearing seal housing.

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

To remove the housing seal, use a punch as shown. Discard seal.

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.

Inspect the crankshaft sleeve and replace if necessary. To remove, 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.

Using an appropriate bearing separator, support the bearing, place separator flats against the bearing, and press off the crankshaft.

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

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