5040307 EVINRUDE * ALTERNATOR ASSEMBLY

Start By:a. remove valve covers 1. Remove four bolts (1) from the turbocharger tube adapter to the aftercooler housing. Loosen the turbocharger compressor housing clamp, and rotate turbocharger tube (2) out of the way of the cylinder head assembly. 2. Remove bolts (3) that hold the valve cover bases to the cylinder head assembly. Remove valve cover bases (4).
To prevent damage to the fuel injection nozzle, hold adapter assembly (5) in position at the top of injection nozzle (6) when fuel line nut (7) is loosened or tightened.
3. Use Tool (A) and a 7/8 5P-0328 Crow Foot Wrench ( in) to loosen the fuel injection line nut at the nozzle end. 4. Use Tool (B) to loosen the nut at the fuel injection line adapter end. Remove inner fuel injection lines (8). Install caps and plugs on all fuel injection line openings to keep dirt out of the fuel system. 5. Remove bolts (9) that hold the rocker shaft assemblies to the cylinder head assembly.6. Remove rocker shaft assemblies (10). 7. Put identification marks on the push rods as to their location in the engine. Remove push rods (11). 8. Put identification marks on the bridges as to their location in the engine. Remove bridges (12) from the dowels on the cylinder head assembly.Install Rocker Shaft Assemblies & Push Rods
1. Put clean engine oil on the bridges and dowels. Install the original bridges in their respective locations. New bridges can be mixed.2. Install bridges (1) on the bridge dowels. While firmly pressing 0.5 to 4.5 kg (1 to 10 lb) straight down on the top contact surface of the bridge, turn the adjusting screw clockwise until contact is made with the valve stem. Turn the screw an additional 1/31/2 20 to 30 degrees ( to of 1 hex on nut). This will straighten the dowel in the guide and compensate for the slack in the threads. Hold the adjusting screw in this position, and tighten the locknut to a torque of 30 4 N m (22 3 lb ft). Install original push rods in their respective locations in the engine. New push rods can be mixed.3. Install push rods (2). 4. Put rocker shaft assemblies (3) in position on the cylinder head assembly.5. Put clean engine oil on the threads of the bolts that hold the rocker shaft assemblies in place. Tighten the bolts first to a torque of 270 25 N m (200 18 lb ft). Start with the bolt in the center of the rocker shaft assembly. Tighten the bolts again to a torque of 450 20 N m (330 15 lb ft). Tighten the bolts again by hand to a torque of 450 20 N m (330 15 lb ft).
Do not cause damage to the O-ring seals on the inner fuel lines.
6. Install inner fuel injection lines (4). Tighten the fuel injection line adapter nuts (5) to a torque of 40 7 N m (30 5 lb ft) with Tool (A).
Do not let the tops of the fuel nozzles turn when the fuel lines are tightened. The nozzles will be damaged if the top of the nozzles turns in the body.
7. Tighten fuel injection line nut (6) to a torque of 40 7 N m (30 5 lb ft) with Tool (B) and a 7/8 5P-0328 Crow Foot Wrench ( in).8. Make adjustments to the valves until the inlet valve clearance is 0.38 mm (.015 in) and the exhaust valve clearance is 0.76 mm (.030 in). See the topic "Valve Clearance Setting" in Systems Operation Testing & Adjusting. Tighten the locknut to a torque of 30 4 N m (22 3 lb ft) and check the adjustments. 9. Install valve cover bases (7) on the cylinder head assembly. Install bolts that hold the valve cover bases in place. Tighten the bolts to a torque of 14 3 N m (10 2 lb ft). 10. Rotate turbocharger tube (8) into position. Place a gasket between the aftercooler housing and adapter, and install four bolts and nuts that hold the tube to the aftercooler housing.11. Tighten turbocharger clamp nut (9) to a torque of 18 3 N m (13 2 lb ft). Lightly hit all around the clamp with a soft faced hammer, and tighten the clamp nut again to the same torque value.End By:a. install valve coversDisassemble Rocker Shaft Assemblies
Start By:a. remove rocker shaft assemblies and push rods 1. Remove retainer (2) from the end of the shafts.2. Remove the washers and rocker arms (1). 3. Remove pins (6) that hold the brackets to each end of the shaft. The center bracket does not have a pin.4. Remove bracket (3), rocker arm (4) and spring (5).Assemble Rocker Shaft Assemblies
1. Put clean engine oil on the shaft.2. Install the bracket and rocker arms for the center bracket.3. Install spring (1), rocker arm (2) and bracket (3). Install the pin that holds the brackets on each end of the rocker shaft. Install the pin until it extends 12.7 1.0 mm (.50 .04 in) from the surface of the bracket. 4. Install rocker arm (4) on each end of the shaft. Install washers (5) as needed to get an assembled clearance of .03 to 1.40 mm (.012 to .055 in) at each end of the shaft. Install the retainer on each end of the shaft.End By:a. install rocker shaft assemblies and push rods