DSS10431I_355442_3.3L RPH Seal Kit_Rev 1.fm
Contents
1. aur ZN 2 6 A gt lt A Starboard View Oil Recirculation Hose Routing Port and Starboard 008207 1 Recirculation fittings 6 of 8 OIL SUPPLY HOSE ROUTINGS Port View MEN 6 i Front View _ O 2 NP o POR O O 1207 Oil tank assembly Oil pick up Oil supply hose Oil filter NL O OKO 979 Q d LM qe 000 Oil pump assembly Oil distribution hoses Oil pressure switch Rear oil manifold Rear oil manifold delivers oil to cylinder sleeves Cylinder 2 Cylinder 4 Cylinder 6 Cylinder 1 Cylinder 3 Cylinder 5 Primary oil manifold delivers so Oll to crankcase fittings and rear oil manifold Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cy2. 1 2 1 2 2 2 4 1 2 1 2 1 1 1 1 1 6 6 1 4 1 2 6 1 1 1 3 1 IMPORTANT The oil supply hose clear tub ing to the rear oil manifold must be installed in the center fitting of the oil injection pump This hose DOES NOT use brass supports The rear oil distribution hoses blue tubing can be installed in any of the rear manifold fittings Position fuel and oil hoses to pre vent hoses from being pinched during assembly Pinched or damaged hoses can restrict fuel or oil flow and result in power head failure 4 of 8 Perform the following procedures when installing replacement powerheads e Adjust timing pointer Refer to Timing Adjust ments in the service manual Index all spark plugs Refer to Spark Plug Indexing in the service manual e Use Evinrude Diagnostics software to start powerhead break in oiling Refer to Power head Break In in the service manual Use Evinrude Diagnostics software to set TPS calibration Refer to TPS Calibration in the service manual Use Evinrude Diagnostics software to make sure engine management software version and revision are current Update as required Prime fuel system Refer to Fuel System Priming in the service manual Prime oiling system Refer to Refer to Oil System Priming in the service manual Use Evinrude Diagnostics software to check engine timing Refer to Timing Adjustments in the service manual Run out
3. understood these instructions completely Torque wrench tightening specifications must strictly be adhered to Should removal of any locking fastener lock tabs locknuts or patch screws be required always replace with a new one When replacement parts are required use Evinrude Johnson Genuine Parts or parts with equivalent characteristics including type strength and material Use of substandard parts could result in injury or product malfunction Always wear EYE PROTECTION AND APPROPRIATE GLOVES when using power tools Unless otherwise specified engine must be OFF when performing this work Always be aware of parts that can move such as flywheels propellers etc Some components may be HOT Always wait for engine to cool down before performing work If you use procedures or service tools that are not recommended in this instruction sheet YOU ALONE must decide if your actions might injure people or damage the outboard This document may be translated into other languages In the event of any discrepancy the English version shall prevail TO THE INSTALLER Give this sheet and the operating instructions to the owner Advise the owner of any special operation or maintenance information contained in the instructions TO THE OWNER Save these instructions in your owners kit This sheet contains information important for the use and maintenance of your engine UT Revision 1 10f8 REPLACEMENT POWERHEAD
4. Outboard Engines EVINRUDE Johnson REPLACEMENT POWERHEAD SEAL KIT P N 5008304 APPLICATION INSTALLATION INSTRUCTIONS This kit is used for Evinrude E TEC liter 90 V6 models Later model outboards do not require all components supplied Older models must be updated with Rear Oil Manifold Kit P N 5008084 SAFETY INFORMATION The following symbols and or signal words may be used in this document A DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury A WARNING Indicates a hazardous situation which if not avoided could result in death or seri ous injury A CAUTION Indicates a hazardous situation which if not avoided could result in minor or mod erate personal injury 1010116 Indicates an instruction which if not followed could severely damage engine components or other property These safety alert signal words mean ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED For safety reasons this kit must be installed by an authorized Evinrude Johnson dealer This instruction sheet is not a substitute for work experience Additional helpful information may be found in other service literature Printed in the United States 2010 BRP US Inc All rights reserved TM and the BRP logo are registered trademarks of Bombardier Recreational Products Inc or its affiliates DSS104311 DO NOT perform any work until you have read and
5. SEAL KIT 2 of 8 REPLACEMENT POWERHEAD SEAL KIT JJ D P N Name of Part 5008304 SEAL KIT 301917 313537 772571 772569 772569 339299 344472 344771 346150 346151 346152 346785 348478 348839 349729 350933 350934 351535 355442 352941 O RING FITTING TEE 5 32 OD Black HOSE 2 5 cut from roll 5 32 ID 140 332721 HOSE 6 5 cut from roll 3 32 ID 093 335803 HOSE 15 cut from roll 3 32 ID 109 338591 SEAL THERMOSTAT GASKET REG RECT COVER THERMOSTAT CLAMP EAR 18 5MM CLAMP EAR 21MM CLAMP EAR 25 6MM CLAMP EAR 14 5MM CHECK CLAMP EAR 17 0MM CLAMP EAR 41 0MM GASKET THROTTLE BODY to REED PLATE GASKET REED PLATE to CRANKCASE GASKET CRANKCASE to ADAPTOR SHEET INSTRUCTION HOSE 3 x 7 64 ID 109 5007017 KIT AY INJECTOR 5007597 PLUG AY QC8WEP 9008084 REAR OIL MANIFOLD KIT Refer to HOSE ROUTINGS on the next pages and in the appropriate Evinrude E TEC service 320107 345359 348513 349898 352336 354118 393233 600905 5007639 TIE STRAP 7 HOSE 1 5 BLUE TUBING HOSE 32 BLUE TUBING HOSE SUPPORT brass FITTING TEE 1 8 OD White OIL SUPPLY HOSE 39 CLEAR TUBING HOSE Fuel supply hose SLEEVE BRAIDED 3 16 28 length MANIFOLD AY OIL manuals as needed for additional assembly information This kit includes components to update older models to sleeve oiling Qty 1 2 1 1 1
6. board and check for water fuel or oil leaks Make sure engine reaches correct operating temperature and does not overheat OIL RECIRCULATION HOSE ROUTINGS Front View Recirculation Hose Routing Front 008205 1 Intake manifold to cylinder Z2 recirculation fitting 2 Lower to upper main bearing recirculation fitting 3 Oylinder recirculation to intake manifold fitting Top View Recirculation Hose Routing Top 008206 1 Intake manifold to cylinder Z2 recirculation fitting 5 of 8 Port View A L pP N UH T B jr Korn Vl a 4 ER L tt D UN gt Sa ST 2 l 3 PA AT l Y HN o v N 2 ANYS C IA LA me 3I j a Sy IN Ti GAYA N pj AA IR o Rc RR
7. linder 6 Rear oil manifold AA IA 008212 7 of 8 Port View Starboard View Oil Supply Hose Routing Port and Starboard 1 Oil supply fittings 2 Oil distribution hose from rear oil manifold to cylinder 1 must be routed in front of oil recirculation fittings 8 of 8 QHO 0 Sy 5 1 A Q O O 008208
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