Service Manual Evinrude E-TEC 40-60 HP Midsection [Exhaust Housing]

Before removing the midsection:

• The gearcase must be removed. Refer to Gear case REMOVAL AND INSTALLATION on p. 267.
• The powerhead must be removed. Refer to Powerhead REMOVAL on p. 205.

Remove the three lower mount cover screws.

Separate lower mount covers from swivel bracket.

Check condition of the lower front mount and two lower side mounts.

1. Lower front mount

1. Lower side mount

Remove the three upper mount to exhaust housing screws. Be sure to support exhaust housing so it does not fall.

Remove exhaust housing from stern bracket.

Exhaust Housing

The exhaust housing contains no serviceable internal parts. The exhaust water valve and the exhaust relief muffler can both be serviced without removing the exhaust housing.

Exhaust Water Valve

Disconnect water valve electrical connector.

Remove screws and bracket holding valve to exhaust housing.

Remove tie straps and disconnect water valve hoses (3) from exhaust housing.

1. Electrical connector
2. Inlet hose
3. Outlet hose

Check that all water passages are clear

1. Fitting, water passage

Install hoses to fittings on exhaust housing.

Place water valve and bracket in position.

Apply Nut Lock to screws, install and tighten 60 to 84 in. lbs. (7 to 9.5 N.m).

1. Exhaust water valve screws

Exhaust Relief Muffler
Remove exhaust relief muffler cover to inspect filter element. Clean or replace as needed.

1. Exhaust relief muffler cover

Apply Gasket Sealing Compound to cover gasket and install cover.

Apply Nut Lock to cover screws and tighten 60 to 84 in. lbs. (7 to 9.5 N.m)

Bring the exhaust housing into position with the stern bracket.

Exhaust Housing

Apply Nut Lock to threads of the upper mount screws. Install the screws and place ground lead under the center screw. Torque screws to 18 to 20 ft. lbs. (24 to 27 N·m).

1. Ground lead

Place the lower thrust washer on the steering shaft and position the lower front mount.

1. Thrust washer
2. Lower front mount

Install lower side mount covers. Install and torque the screws in stages to 16 to 18 ft. lbs. (22 to 24 N·m) following sequence shown.

Torque sequence

Install gearcase. Refer to Gearcase REMOVAL AND INSTALLATION on p. 267.

Install powerhead. Refer to Powerhead INSTALLATION on p. 228.