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

Inspect center main bearing and split sleeves for excess wear, nicks, or scratches. Replace, if necessary.

24381

Inspect crankshaft rod bearings for excess wear,nicks, or scratches. Replace, if necessary.

IMPORTANT: Proceed slowly. Make no forced assemblies unless a pressing operation is called for. All internal components must be perfectly clean and lightly coated with outboard lubricant.

IMPORTANT: Use new wrist pin retaining rings, gaskets, seals, and O-rings during assembly

Crankshaft Assembly

Oil the end of the crankshaft. Use Crankshaft Bearing/Sleeve Installer, P/N 338647, and place a new lower main bearing onto crankshaft with lettered side facing the tool. Install bearing until it seats on the crankshaft.

29020

Oil the end of the crankshaft. Use Crankshaft Bearing/Sleeve Installer, P/N 338647, to drive a new sleeve onto the crankshaft until the installer contacts the lower main bearing.

29021

If the installer sticks on the sleeve after installation, thread Slide Hammer, P/N 391008, into installer and pull it off.

IMPORTANT: Inspect sleeve after installation. Sleeve must not be used if surface is damaged.

Use retaining ring pliers to install bearing retaining ring with sharp edge facing away from bearing.

Lubricate a new driveshaft O-ring and lightly lubricate crankshaft splines with Moly Lube. Install O-ring in sleeve.

29022

1. Bearing retaining ring
2. O-ring

Lubricate the center main bearings and split sleeves with outboard lubricant and install them in their original positions. The split sleeve ring grooves must face toward driveshaft (lower) end of crankshaft when installed.

005282

Lightly coat the outside edge of a new lower housing seal with Gasket Sealing Compound. Press against outer case of the seal to install seal in the lower housing with extended lip facing down. Lubricate seal lip with Triple-Guard grease.

002036

1. Extended lip

002037

1. Seal lip

Install a new O-ring on the lower housing. Before installing crankshaft into cylinder block, apply a thin coat of Gasket Sealing Compound to outer edge of O-ring.

Place lower seal housing on crankshaft.

005280

1. O-ring

Thoroughly clean upper seal area of the crankshaft. Install new upper seal on crankshaft. Do not apply sealer to outside diameter of the seal.

It is very important that the pistons in this engine are installed in the correct location and direction. Engine damage will occur if installed incorrectly.

New pistons are stamped “PORT” or “STBD,” and “EXH.” These markings should be turned toward the exhaust side (center) of the block. The splash bowl on the dome of the piston will be located toward the flywheel and opposite the exhaust port.

005283

1. Stamped markings

It is also very important that the connecting rods are installed with the align ment dots and the diagonal oil hole facing up, toward the flywheel.

002055

1. Oil hole
2. Raised dots

Apply Needle Bearing Grease to the wrist pin bearings. Install the bearings in the small end of the connecting rod. Align bearings with Wrist Pin Bearing Tool, P/N 336660.

31794

Place the two wrist pin thrust washers on the tool with flat side of the washers facing out.

DR3480
31793

1. Wrist pin thrust washers

Oil the wrist pin bore and wrist pin. Place connecting rod, with bearings, washers, and tool, into the piston with the alignment dots facing the top of the piston.

Install wrist pin through piston and connecting rod, pushing bearing tool out through the piston.

46521

Use Wrist Pin Cone, P/N 318600, and Driver, P/N 318599, to install new wrist pin retaining rings in each wrist pin hole. Gap of retaining ring faces away from notch in piston.

46522

46523

1. Gap of retaining ring
2. Notch in piston

Installing Pistons

When all pistons and connecting rods are assembled, install piston ring sets. Be sure rings are installed in the cylinder used to test ring end gap. Refer to POWERHEAD INSPECTION on p. 249.

IMPORTANT: Be sure gap of ring fits squarely around dowel pin.

002048

Before continuing, make sure that all Gel-Seal II has been removed from the cylinder block and crankcase mating flanges. If traces of hardened Gel-Seal II are left, main bearings could be misaligned. Refer to CYLINDER BLOCK CLEANING on p. 248.

Coat pistons, rings, cylinder walls, and an appropriate ring compressor with outboard lubricant.

Center connecting rod in piston and locate piston rings on dowel pins. Place appropriate ring compressor on piston.

Slide piston and rod assembly into the correct cylinder, as marked during disassembly. Guide connecting rod through cylinder block to avoid scratching cylinder wall.

005284

1. Ring compressor

Install a new thermostat seal in cylinder head with side marked “TO CYL HEAD” facing toward thermostat.

Refer to THERMOSTAT SERVICING on p. 235 before installing cylinder head.

Lightly lubricate new cylinder head O-rings with Triple-Guard grease and install in cylinder head.

005286

1. O-Ring

Apply soapy water to water dam and insert into block.

005287

1. Water dam

Apply a 1/16 in. (2 mm) bead of RTV adhesive around each water passage on the block and cylinder head as shown.

005288

1. RTV adhesive (24 locations)
2. Thermostat seat area

Install cylinder head with the thermostat toward the top. Apply outboard lubricant to screw threads and install the cylinder head screws. DO NOT use any sealant on threads

Following sequence stamped on cylinder head, tighten all screws in stages to a torque of 168 to 192 in. lbs. (19 to 21.5 N·m).

005289

1. Cylinder head screws

Apply Gasket Sealing Compound to lower oil seal groove in cylinder block. DO NOT put any sealer in upper seal groove.

Check that main bearing alignment dowel pins are seated in the block.

005290

1. Gasket Sealing Compound
2. Dowel pins
3. No sealer here

Push all pistons to the top of cylinders. Remove numbered connecting rod caps. Gently lower crankshaft into place.
• Turn all crankcase seal ring gaps to face up.
• Align tab on lower bearing seal housing with hole in crankcase.
• Align upper oil seal in groove.
• Locate each main bearing on its dowel pin. A mark placed on the bearing race opposite the dowel pin hole will help in the alignment process.

005291

1. Gaps (up)
2. Lower seal housing
3. Upper oil seal
4. Alignment marks

Lubricate each crankpin and bearing assembly with outboard lubricant. Slowly pull connecting rod up to crankshaft and install bearing halves.

005298

Lubricate rod cap screw threads and under screw head mating surface with outboard lubricant.

Align dot on rod cap with dot on the connecting rod.

Install rod cap screws finger tight (NO MORE than 6 in. lbs. (1 N·m) maximum).

49080

IMPORTANT: Be sure alignment dot on rod cap matches dot on rod and that both dots face flywheel.

53628

1. Alignment dots

Tightening rod cap screws without Alignment Fixture, P/N 396749, or using an incorrect procedure could cause permanent damage to the connecting rod and crankshaft. To maintain accurate torque values, keep torque wrench extension length to a minimum.

Install Rod Cap Alignment Fixture, P/N 396749, before tightening rod cap screws. Align the flat marked “SET” on the rod adjustment stop with the arrow on the frame. Position stop at the center setting (one line showing). Rotate adjustment
knob 180° to lock in position.

002484

1. Center position, one line showing

Secure restraining jaw “C” and forcing jaw “D” to frame.

21591c
Restraining Jaw “C”

21594c
Forcing Jaw “D”

Apply a light coat of outboard lubricant to the corners of the connecting rod and rod cap. Place frame on connecting rod using the following procedure:
• Position frame onto the connecting rod so the contact area of the jaw is centered on the side of the rod.
• Tighten forcing screw until jaws contact connecting rod.
• Slide frame down until adjustment stop contacts the rod cap. The groove lines on the jaws must be centered on the rod/crankpin diameter.
• Tighten the forcing screw to a torque of 14 to 16 in. lbs. (1.6 to 1.8 N·m).

005297

1. Forcing screw
2. Adjustment stop
3. Groove line

IMPORTANT: Make sure that frame is squarely in position and that rod and cap are aligned.

Loosen both rod cap screws one-quarter turn.

Use Torquing Socket, P/N 331638, to tighten rod cap screws in three stages:
• Apply first torque of 40 to 60 in. lbs. (5 to 7 N·m) to both rod cap screws.
• Tighten screws to a torque of 14 to 16 ft. lbs. (19 to 21.7 N·m).
• Apply final torque of 30 to 32 ft. lbs. (41 to 43 N·m).

005299

IMPORTANT: If a new screw is used, it must be installed as above. Then, it must be removed, relubricated, and installed again.

Loosen forcing screw and remove the frame.

Test at least three corners of the rod and cap joint with a pick. Joint must be smooth with no step.

005300

Thoroughly clean and degrease the mating flanges of the crankcase and cylinder block with a non-petroleum based solvent, such as isopropyl alcohol or acetone, and let air dry.

IMPORTANT: DO NOT allow solvent to get on internal components. Clean only the mating flanges.

Apply Gasket Sealing Compound to lower oil seal groove in crankcase. DO NOT put any sealer in upper seal groove.

Use a small brush with a tapping motion to apply a thin, even coat of Gel-Seal II sealant to the crankcase mating flange. The sealer must not come within 1/4 in. (6.4 mm) of bearings.

003874

IMPORTANT: Gel-Seal II has a shelf life of at least one year when stored at room temperature. Test the Gel-Seal II or replace it if the age of the tube cannot be determined. Using old Gel-Seal II could cause crankcase air leaks.

IMPORTANT: The use of Locquic Primer is NOT recommended. If primer is used, crankcase halves must be assembled and tightened within ten minutes after the Gel-Seal II has been applied.

Lower the crankcase into place. Make sure that upper oil seal and lower seal housing are seated in grooves.

Apply outboard lubricant to the main bearing screws. Install screws finger tight, no more than 60 in. lbs. (7 N·m).

005308

When the crankcase is seated, install and firmly seat the crankcase taper pin.

005307

Tighten main bearing screws in stages to a final torque of:
• 31 to 35 ft. lbs. (42 to 47.5 N·m).

Start in the center and work outward in a spiral pattern.

005313

Apply Nut Lock to crankcase flange screws. Install screws and tighten to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).

005306

Test that the crankshaft spins freely without binding.

IMPORTANT: After powerhead has been assembled, allow at least two hours for Gel-Seal II to cure before running outboard.

Lubricate shift linkage bosses at the base of the crankcase with Triple-Guard grease. Insert bushings into bosses.

Apply Triple-Guard grease to the shaft of the shift lever assembly. Guide shaft through bushings in crankcase.

Install shift rod lever and tighten retaining screw 60 to 84 in. lbs. (7 to 9.5 N·m).

Apply Triple-Guard grease to shoulder of shift arm screw and Nut Lock to threads. Install arm, screw, and washer and tighten screw to a torque of 120 to 144 in. lbs. (13.5 to 16.5 N·m).

005294

1. Shift arm screw
2. Shift lever screw

Apply Nut Lock to threads of throttle lever screw.

Insert spring into cavity of throttle lever.

Install lever, screw, and washer on crankcase and hook spring on rib as shown. Tighten screw to a torque of 120 to 144 in. lbs. (13.5 to 16.5 N·m).

005259

1. Throttle lever spring

Apply Nut Lock to threads of throttle cam screw. Install cam, screw, and washer on cylinder block and tighten screw to a torque of 120 to 144 in. lbs. (13.5 to 16 N·m).

005293

1. Throttle cam screw

IMPORTANT: Do not lubricate throttle levers or shoulder screws.

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

Install oil recirculating hoses and check valves. Refer to OIL RECIRCULATION DIAGRAMS – V4 on p. 212, OIL RECIRCULATION DIAGRAMS – V6 on p. 214, or POWERHEAD VIEWS on p. 267.

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

Install shift linkage. Refer to Shift Linkage Installation on p. 260.

Install throttle linkage. Refer to Throttle Linkage Installation on p. 261.

Install fuel injectors and ignition coils. Refer to Fuel Injector Installation on p. 200.

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

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

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

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

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

Install the electric starter. Refer to Starter Installation on p. 175.

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