INSTALLATION
Apply Permatex No. 2 to edge of the inner exhaust area of both sides of a new base gasket. Leave the other areas of gasket dry.
To ensure proper sealing, the mating surfaces must be clean and free of oil, grease, and foreign matter.
- Inner exhaust area
Coat the driveshaft splines with Moly Lube. Do not apply lubricant to end of driveshaft.
Use Lifting Fixture, P/N 396748, to slowly lower powerhead onto exhaust housing.
Apply Gasket Sealing Compound to the threaded portion of the 3/8 in. diameter powerhead screws. Install all fasteners loosely before torquing any.
Torque the 3/8 in. diameter powerhead screws to 18 to 20 ft. lbs. (25 to 27 N·m) in the sequence shown.
Apply Gasket Sealing Compound to the 5/16 in. diameter powerhead screws and torque the screws to 144 to 168 in. lbs. (16 to 19 N·m) in the sequence shown.
IMPORTANT: In order to achieve proper sealing and prevent gasket damage, the powerhead mounting screws must be retorqued after engine has reached operating temperature and has been allowed to cool.
Install two front and one rear powerhead nuts. Tighten nuts 144 to 168 in. lbs. (16 to 19 N·m).
- Front powerhead nut (2)
- Rear powerhead nut
Install water hoses and exhaust back pressure hose.
- Cooling hose (from exhaust plenum)
- Cooling hose (from vapor separator)
- Speedometer hose
- Cooling hose (to exhaust plenum)
- Exhaust back pressure hose (to EMM)
- Cooling hose (from block)
Route power trim harness through clamp and connect to engine harness.
- Trim harness
- Clamp
- Trim/tilt connectors
Align gearcase shift rod and linkage, and install the shift rod pin. Tighten 60 to 84 in. lbs. (7 to 9.5 N·m).
- Shift rod pin
Thoroughly clean the crankshaft and flywheel tapers with Cleaning Solvent and let air dry.
Install flywheel key in crankshaft with flat side parallel to crankshaft centerline.
Apply a thin, even coat of Nut Lock to the inside taper of the flywheel.
IMPORTANT: DO NOT apply too much Nut Lock on flywheel taper to prevents Nut Lock from migrating into the upper seal of the crankshaft.
Align the crankshaft key and flywheel keyway, and install flywheel. Coat the threads of a new flywheel nut with Gasket Sealing Compound, and torque the nut to 140 to 145 ft. lbs. (190 to 197 N·m).
Install air temperature sensor, air silencer, and flywheel cover. Tighten flywheel cover screws 30 to 42 in. lbs. (3.5 to 5 N·m).
- Air temperature sensor
Install lower engine covers and tighten screws.
- Lower cover screws
Connect fuel and oil hoses to connectors. Install battery cables, control cables, and electrical cables.
IMPORTANT: Perform the following procedures before returning outboard to service:
- Index all spark plugs. Refer to Spark Plug Indexing on p. 155.
- Prime oiling system. Refer to PRIMING on p. 205.
- Prime fuel system. Refer to Fuel System Priming on p. 65.
- Use the Evinrude Diagnostics Software program to initiate powerhead break-in. Refer to Powerhead Break-In on p. 109.
- Check all linkage adjustments, adjust timing pointer, and perform timing verification. Refer to TIMING ADJUSTMENTS on p. 154.
- Run outboard and check for water, fuel, or oil leaks.
- Confirm that engine reaches correct operating temperature and does not overheat.
