5007824 EVINRUDE 2009 Service Manual Set

start by:a) remove fuel injection pump housing and governor as a unitb) remove fuel transfer pumpc) remove governor
The fuel injection pumps can not be removed before the timing pin is installed.
1. Remove the timing pin. Install a bolt up side down through one of the holes in the flange. Install the pin into timing hole, move the rack until the timing pin goes through the notch in rack. Push timing pin down until head of bolt (1) makes contact with housing. 2. Remove fuel injection pumps (3). Put identification on the pumps as to their location in the pump housing.
During disassembly and assembly of fuel injection pumps, do not cause damage to plunger surfaces. The bodies and plunger are special fitted, and the parts can not be changed with other bodies or plungers.
3. Put the pump in a vise as shown. Use tool (A) to loosen bonnet (4). 4. Remove bonnet (4), spring (6) and check valve (5) from the body.5. Remove and disassemble the remainder of the fuel injection pumps in the same way.6. Remove cover (2). Remove the rack position indicator lever. 7. Remove plunger (9), washer (8), spring (7) and O-ring seal (10) from the body. 8. Remove timing pin (11). 9. Remove eight bolts (12) and remove adapter (13) from the fuel injection pump housing. 10. Remove rack (14) from the fuel injection pump housing.
Do not remove or install the spacers in the lifters. A spacer that has been installed wrong can cause an engine failure.
11. Put identification on the lifters for installation purposes. Remove lifters (15) from the fuel injection pump housing. 12. Remove the locks and bolts from drive gear (16) for the fuel transfer pump. Remove gear (16). 13. Remove cover (17) and gasket from the bottom of the fuel injection pump housing. 14. Remove the locks, bolts, plate and shims that hold the variable timing unit in place. Remove variable timing unit (18) from the fuel injection pump housing. 15. Remove camshaft (19) from the fuel injection pump housing. 16. Remove bearings (20) for the rack from the fuel injection pump housing with tooling (C). 17. Remove the camshaft bearing from the fuel injection pump housing with tooling (B) as shown. 18. Remove bearing (21) for the variable timing unit from the fuel injection pump housing.Assemble Fuel Injection Pump Housing
1. Inspect the parts for damage and make replacements if needed. Make sure all the parts are clean. Put 5P0960 Multipurpose Type Grease on the O-ring seals. 2. Install the bearing for the variable timing unit with the oil hole in the bearing in alignment with the hole in the fuel injection pump housing with tooling (A). The inside diameter of the bearing after assembly must be 4.0054 .0019 in. (101.737 0.048 mm). 3. Install four camshaft bearings (1) in the fuel injection pump housing with tooling (C). Make sure the bearing junction (joint) is at an angle of 60 15° from the vertical centerline away from the rack. The inside diameter of the bearings after assembly must be 2.6258 .0019 in. (66.695 0.048 mm). 4. Install the bearing for the rack in the fuel injection pump housing with tooling (B). The rack front bearing must be .38 in. (9.7 mm) from the front surface of housing. The rack rear bearing must be installed 6.00 in. (15.2 cm) in from the variable timing unit end of fuel injection pump housing. The inside diamter of the bearings after assembly must be 0.6125 .0015 in. (15.558 0.038 mm). 5. Put clean oil on the camshaft and install camshaft (2) in the fuel injection pump housing.6. Install drive gear (3) for the fuel transfer pump on the camshaft.
Install original amount of shims. There must be an end clearance (backlash) of .002 to .005 in. (0.05 to 0.13 mm) between the variable timing unit gear and the governor pinion gear when the governor drive is installed. Remove or add shims if necessary.
7. Put variable timing unit (4) in position and install the shims, plate, locks and bolts that hold it in place. 8. Install the gasket and plate (5) on the bottom of the fuel injection pump housing. If new lifters have been installed, it will be necessary to set the fuel pump timing dimension. See FUEL PUMP TIMING DIMENSION SETTING (OFF ENGINE) in TESTING AND ADJUSTING. 9. Install lifters (6) in the fuel injection pump housing in the same place from which they were removed. 10. Slide rack (7) into position in the fuel injection pump housing. 11. Install timing pin (8) with a bolt up through the flange as shown. This will hold the rack in the correct position and will let the fuel injection camshaft turn.
Do not try to install the fuel injection pumps if the rack is not in the correct position.
12. Install rack position lever (9). Make sure the lever is in alignment with the groove in the rack. Install the cover. 13. Put the gasket and adapter (10) in position on the fuel injection pump housing and install the bolts that hold them in place.14. Assemble the fuel injection pumps as follows: a) Put clean fuel on the parts. b) Install O-ring seal (14) on the body. Install spring (11), washer (12) and plunger (13) in the body. c) Install check valve (15), spring (16) and bonnet (17) in the body. d) Tighten bonnet (17) to a torque of 145 5 lb.ft. (195 7 N m) with tooling (D) and a torque wrench. 15. Install fuel injection pumps (18) in the fuel injection pump housing in the same place from which they were removed as follows: