Service Manual 5008330_55 HP MFE Powerhead [Powerhead Installation]

Install the reed plate and throttle body assemblies. Refer to Intake Manifold Service on p. 151.

Install oil recirculating hoses and check valves. Refer to OIL RECIRCULATION DIAGRAM on p. 158, or POWERHEAD VIEWS on p. 208.

Install thermostat assembly. Refer to THERMOSTAT SERVICING on p. 176.

Install pressure valve assembly. Refer to PRESSURE RELIEF VALVE SERVICING on p. 177.

Install shift linkage. Refer to Shift Linkage Installation on p. 202.

Install throttle linkage. Refer to Throttle Linkage Installation on p. 203.

Install fuel injectors and ignition coils. Refer to Fuel Injector Installation on p. 149 and IGNITION COIL SERVICING on p. 123.

IMPORTANT: All injectors must be installed in their original location. Improper injector installation can result in powerhead failure.

Install stator and flywheel. Refer to FLYWHEEL AND STATOR SERVICING on p. 121.

Install electrical harness and EMM. Refer to POWERHEAD VIEWS on p. 208 and EMM SERVICING on p. 92.

Install fuel pump assemblies, fuel manifolds, and filter. Refer to FUEL COMPONENT SERVICING on p. 144.

Install the oil tank and oil injection hoses. Refer to Oil Tank Assembly on p. 166.

To prevent fire and explosion hazard, make sure all electrical and ignition wiring is routed and clamped in original positions.

Apply Permatex No. 2 to both sides of a new base gasket around the exhaust port only. Install gasket on exhaust housing. To ensure proper sealing, mating surfaces must be clean and dry.

• 1. Exhaust port
• 2. Clean surface
• 3. Moly Lube

Coat the driveshaft splines with Moly Lube. Do not apply lubricant to end of driveshaft.

Use Lifting Fixture, P/N 396748, and hoist to slowly lower powerhead onto exhaust housing. If necessary, rotate flywheel in a clockwise direction to align crankshaft and driveshaft splines.

Apply Triple-Guard grease to the threads, and Gasket Sealing Compound to the cylindrical shank of the powerhead screws.

Loosely install all powerhead screws before tightening:

• 1. Powerhead screws

Tighten the eight powerhead screws to a torque of 18 to 20 ft. lbs. (24 to 27 N·m) in the sequence shown.

Large screw torque sequence, 1 – 10

IMPORTANT: Retighten powerhead mounting screws after outboard has been run at full operating temperature and allowed to cool.

Place the shift rod in the shift rod lever. Install the retaining pin and washer. Tighten pin to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).

• 1. Shift rod screw

Check shift linkage adjustment. Refer to Shift Linkage Adjustment on p. 207.

IMPORTANT: Make sure the gearcase shifts completely into both forward and reverse and that propeller shaft spins freely in neutral.

Apply Nut Lock to threads of exhaust water valve screws and tighten to a torque of 60 to 84 in. lbs. (7 to 9.5 N.m).

• 1. Exhaust water valve

Connect cooling water hoses to exhaust housing.

• 1. Overboard indicator hose
• 2. Drain hose

Connect exhaust water valve connector. Secure cables in clamps.

Install throttle cable and tiller shift rod.

1. Cable anchor
2. Anchor screw
3. Cable retainer
4. Shift rod retainer

Refer to Throttle Cable Adjustment on p. 231.

Install recoil starter ratchet and housing on outboard. Refer to RECOIL STARTER INSTALLATION on p. 271.

• 1. Starter housing screws (3)

Install the lower engine covers. Refer to LOWER COVER SERVICE on p. 73.

Adjust shift linkage as follows:

• Loosen adjustment screws on shift lever.
• Be sure that ball is centered in detent assembly.
• Adjust shift lever so that the screw hole in shift rod lever lines up with the hole in the gearcase shift rod when gearcase is in neutral.
• When correctly adjusted, the shift lever will be parallel with the vertical line of the outboard, and the distance between the shift lever pin and the center of the shift cable trunnion pocket should be approximately 7 in. (17.8 cm).

IMPORTANT: The shift rod height is the most critical of these adjustments and should not be moved during this procedure. Refer to SHIFT ROD ADJUSTMENT on p. 244.

• Tighten adjustment screws to 60 to 84 in. lbs. (7 to 9.5 N·m).

• 1. Adjustment screws
• 2. Shift detent assembly
• 3. Shift lever pin
• 4. Trunnion pocket
• 5. 7 inch dimension

After installing a new or rebuilt powerhead, perform the following procedures before returning outboard to service:

• Adjust timing pointer.
• Index all spark plugs. Refer to Spark Plug Indexing on p. 63.
• Use Evinrude Diagnostics software to start powerhead break-in oiling. Refer to Powerhead Break-In on p. 89.
• Use Evinrude Diagnostics software to set TPS calibration. Refer to TPS Calibration on p. 126.
• Use Evinrude Diagnostics software to make sure engine management software version and revision are current. Update as required.
• Prime fuel system.
• Prime oiling system. Refer to Oiling System Oil Supply Priming on p. 39.
• Use Evinrude Diagnostics software to check engine timing. Refer to TIMING ADJUSTMENTS on p. 124.
• Run outboard and check for water, fuel, or oil leaks.
• Make sure engine reaches correct operating temperature and does not overheat.