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*353030*Printed in the United States.© 2006 BRP US Inc. All rights reserved.TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.

POWERHEAD REPLACEMENT KITINSTALLATION INSTRUCTIONS

APPLICATIONUse this instruction sheet when installing powerhead replacement kits on Evinrude® E-TEC™ 60° Voutboards, 115 – 200 Hp. DO NOT install on any other models.

SAFETY INFORMATIONFor safety reasons, this kit should be installed by anauthorized Evinrude®/Johnson® dealer. This instruc-tion sheet is not a substitute for work experience. Ad-ditional helpful information may be found in otherservice literature for your engine.This instruction sheet uses the following signal wordsidentifying important safety messages.

IMPORTANT: Identifies information that will helpprevent damage to machinery and appears next toinformation that controls correct assembly and oper-ation of the product.These safety alert signal words mean:ATTENTION!BECOME ALERT!YOUR SAFETY IS INVOLVED!

Always follow common shop safety practices. If youhave not had training related to common shop safetypractices, you should do so to protect yourself, aswell as the people around you.It is understood that this instruction sheet may betranslated into other languages. In the event of anydiscrepancy, the English version shall prevail.DO NOT do any repairs until you have read the in-structions and checked the pictures relating to the re-pairs.Be careful, and never rush or guess a service proce-dure. Human error is caused by many factors: care-lessness, fatigue, overload, preoccupation,unfamiliarity with the product, and drugs and alcoholuse, to name a few. Damage to a boat and outboardcan be fixed in a short period of time, but injury ordeath has a lasting effect.When replacement parts are required, useEvinrude/Johnson Genuine Parts or parts with equiv-alent characteristics, including type, strength andmaterial. Using substandard parts could result in in-jury or product malfunction.Torque wrench tightening specifications must bestrictly followed. Replace any locking fastener (lock-nut or patch screw) if its locking feature becomesweak. Definite resistance to turning must be felt whenreusing a locking fastener. If replacement is specifiedor required because the locking fastener has becomeweak, use only authorized Evinrude/Johnson Genu-ine Parts.If you use procedures or service tools that are notrecommended in this instruction sheet, YOU ALONEmust decide if your actions might injure people ordamage the outboard.

DANGERIndicates an imminently hazardous situa-tion which, if not avoided, WILL result indeath or serious injury.

WARNINGIndicates a potentially hazardous situationwhich, if not avoided, CAN result in severeinjury or death.

CAUTIONIndicates a potentially hazardous situationwhich, if not avoided, MAY result in minoror moderate personal injury or propertydamage. It also may be used to alertagainst unsafe practices.

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POWERHEAD REPLACEMENT KIT (Evinrude E-TEC 60° V 115–200 HP)

005278P/N Name of Part Qty P/N Name of Part Qty

- POWERHEAD ASSEMBLY 1 349729 CLAMP, 41.0 mm -muffler grommets 2352909 GASKET, C/C to exhaust housing - V4 1 320107 TIE STRAP, Overboard indicator hose 1351458 GASKET, C/C to exhaust housing - V6 1 to vapor separator

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REQUIRED TOOLSIMPORTANT: Alignment Pin Kit, P/N 5007167,must be used when installing a powerhead on anyEvinrude E-TEC 60° V model outboard.

REMOVAL

Disconnect the power trim/tilt switch connector.

Remove lower engine cover screws and port andstarboard covers.

Remove flywheel cover and rear shroud.

Remove air temperature sensor from air silencer.Remove the air silencer.

1. Alignment pin tools

WARNINGProtect against hazardous fuel spray.Before starting any fuel system service,carefully relieve fuel system pressure.Refer to Service Manual.To prevent accidental starting while ser-vicing, disconnect the battery cables atthe battery.

005246

1

1. Lower cover screws 005242

005248

005272

1

1

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Remove screw and washer from shift rod lever torelease the lower shift rod.

Disconnect power trim connectors.

V4 MODELSDisconnect electrical harness from exhaust valveactuator. It is not necessary to remove actuatorfrom exhaust housing.

ALL MODELSDisconnect water overflow hose from vapor sepa-rator. Remove clamps and muffler assembly fromrear of powerhead.

Remove the four small powerhead screws, sevenlarge powerhead screws, and the upper mountscrews.

1. Shift rod screw 005253

1. Tilt limit switch connector2. Sending unit connector

005254

3. Tilt relay connector 005255

1

2

1

1

1. Actuator connector 005247

1. Overflow indicator hose2. Muffler clamps

005243

1. Large powerhead screws2. Small powerhead screws3. Upper mount screws

005273

1

2

1

3

2

2

1

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Install Lifting Tool, P/N 342672, on crankshaft.Tighten mounting screw securely using anAllen 1/4 in. hexagonal wrench. Attach suitablechain hoist to lifting tool.

With weight of powerhead supported by hoist, usea suitable tool to carefully separate the power-head from exhaust housing.

IMPORTANT: Do not damage the powerheadadapter mating surfaces when separating.

Remove the powerhead.

INSTALLATIONApply Permatex No. 2 to both sides of a new basegasket around the exhaust ports only. Install gas-ket on adapter. To ensure proper sealing, matingsurfaces must be clean.

IMPORTANT: V4 and V6 base gaskets are NOTinterchangeable. Be sure to use the correct part.

Coat the driveshaft splines with Moly Lube. Do notapply lubricant to end of driveshaft.

Use Lifting Tool, P/N 342672, and hoist to slowlylower powerhead onto exhaust housing. If neces-sary, rotate flywheel in a clockwise direction toalign crankshaft and driveshaft splines.

005260

005259

1. Permatex No. 2 005258

005276

1

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Install pins from Alignment Pin Kit, P/N 5007167,as shown. Tighten pins until fully seated.

Apply Triple-Guard grease to the threads, andGasket Sealing Compound to the shank of thepowerhead screws.

Apply Triple-Guard grease to upper mount screwthreads.

With alignment pins in place, loosely installremaining powerhead screws and upper mountscrews.

• Torque the large powerhead screws 1 through 4to 20 to 22 ft. lbs (27 to 30 N·m).

• Remove Alignment Pins and torque screws 5through 7 to 20 to 22 ft. lbs (27 to 30 N·m).

• Torque the four small powerhead screws to 60to 84 in. lbs. (7 to 9.5 N·m).

• Torque upper mount screws to 110 to 130 ft. lbs.(149 to 176 N·m). Confirm that screw heads aretight against steering arm.

IMPORTANT: Retorque powerhead mountingscrews after outboard has been run at full operat-ing temperature.

Position the shift rod in the shift rod lever. Installthe retaining screw and washer. Torque screw to60 to 84 in. lbs. (7 to 9.5 N·m).

IMPORTANT: Confirm that gearcase shifts solidlyinto both forward and reverse and that propellershaft spins freely in neutral.

005274

005275

1. Large powerhead screws2. Small powerhead screws3. Upper mount screws4. Alignment pin tool

005277

3

2

1

2

1

4

Large screw torque sequence, 1–7Small screw torque sequence, A–D

005244

1. Shift rod screw 005253

1 2

3

4

5

6

7

AlignmentPin here

A B

C D

AlignmentPin here

1

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V4 MODELSApply Electrical Grease to exhaust valve actuatorelectrical connector and install on actuator.

IMPORTANT: Leave enough slack in harness sothat lower cover will not pull it away from actuator.

ALL MODELSConnect the power trim connectors.

Install air silencer and air temperature sensor.

Install rear shroud and flywheel cover.

Install the lower engine covers and tighten thescrews.

1. Actuator connector 005247

1. Tilt limit switch connector2. Sending unit connector

005254

3. Tilt relay connector 005255

1

2

1

1

005272

005248

1. Lower cover screws 005242

1

1

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Connect trim/tilt switch connector.

IMPORTANT: Perform the following proceduresbefore returning outboard to service. Refer to Ser-vice Manual:• Use the Evinrude Diagnostics Software pro-

gram to make sure powerhead break-in hasbeen started.

• Prime fuel system.• Prime oiling system.• Check timing pointer and engine timing.• Calibrate throttle position sensor (TPS).

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