5040543 EVINRUDE * PROPELLER SHAFT HOUSING

3. Remove the bolts and remove intake elbow (1) from the cylinder head. 4. Disconnect fuel lines (2) and (4) from fuel manifold (3). Remove bolts (5) and remove fuel manifold (3).5. Remove rocker shaft and push rods. See REMOVE ROCKER SHAFTS AND PUSH RODS for this procedure. 6. Remove the bolts and cover (6) from under the cylinder head to be removed. 7. Remove bolt (8) and cap (7) that hold the fuel control lever to the fuel control shaft. 8. Remove bolts (13) to remove lever assembly (9) and rod assembly (14) as a unit from the cylinder head. 9. If necessary use tool (A) to turn the flywheel until the camshaft is moved in a position so rod assembly (14) can be removed between the engine block and camshaft.10. Remove bolt (10) and clamp (12) from fuel injector (11).
Do not put a force on the fuel injection rack or cause damage to it when the injectors are removed.
11. Use a pry bar to remove injector (11) from the cylinder head. 12. Remove fuel lines (17), bracket (16) and elbows (15) from the cylinder head.13. Remove bolts (18) and (20) to remove valve cover base (19) from the cylinder head. 14. Use tooling (B) to fasten a hoist to cylinder head (22). Remove bolts (21) and (23) to remove cylinder head (22) from the engine. The weight of the cylinder head is 45 kg (100 lb.).Install Cylinder Heads
1. Thoroughly clean the spacer plates and bottom surface of the cylinder heads. Install a new head gasket and seals. Do not use any adhesives. A new spacer plate gasket must be installed when the cylinder head is removed. See REMOVE AND INSTALL SPACER PLATE. 2. Fasten a hoist and tooling (A) to the cylinder head with two 3/8"-16 NC bolts and washers as shown. Put the cylinder head into position on the spacer plate. 3. Put clean engine oil on the threads of the cylinder head bolts. Install the cylinder head bolts and washers. Tighten the bolts in the following sequence: a) Tighten all of the bolts to a torque of 30 5 N m (22 4 lb.ft.).b) Tighten bolts 1 through 8 in number sequence to a torque of 270 35 N m (200 25 lb.ft.).c) Tighten bolts 1 through 8 in number sequence to a torque of 450 20 N m (330 15 lb.ft.). 4. Install bolts (3) and the washers to hold the cylinder head to the engine.5. Make sure the O-ring seals are installed around the two dowels in the bottom of valve cover base (2). Put the gasket and base (2) in position and install the bolts to hold them to the cylinder head.6. Install elbows (1) with a gasket on he cylinder head. 7. Install bracket (5) and fuel lines (6) on the cylinder head.8. Make sure the three O-ring seals are installed on injector (4) and put clean engine oil on them and in the bore for the injector.
Do not tap or hit on the injector follower to install the injector. Damage and failure of the injector can be the result.
To prevent a carbon deposit between the injector and the injector bore, make sure the injector body (especially the tapered area) and the injector bore are clean and free of foreign material.9. Put the injector (4) in position. Install the clamp, washer and bolt. Tighten the bolt to push injector (4) all the way in its bore. Tighten the bolt to a torque of 65 7 N m (48 5 lb.ft.).10. Check to make sure the fuel injection rack moves freely by hand in the injector after the injector is installed.11. Install fuel control rod assembly (7) in the cylinder head and engine block. If necessary, use tool (B) to turn the engine flywheel until the camshaft moves enough to permit the lever of rod assembly (7) to move into position. 12. Connect lever assembly (8) to the control rod assembly. Make sure lever assembly (8) is engaged correctly with the fuel injection rack and install the two bolts and washers to hold it in place.13. See TESTING AND ADJUSTING section for the correct adjustment of the fuel injection control group. 14. Make sure the lever for the fuel control rod assembly is in position on control shaft (9) and install the bolt and cap (10). 15. Install cover (12) and seal (11) over the camshaft and control shaft (9).16. Install the rocker shafts and push rods. See INSTALL ROCKER SHAFTS AND PUSH RODS for this procedure. 17. Put clean engine oil on the O-ring seals and install fuel manifold (14). Connect fuel lines (6) and (13) to fuel manifold (14). 18. Put the gaskets and intake elbow (15) in position and install the bolts to hold intake elbow (15) in place.19. Turn on the fuel supply to the engine.20. Fill the cooling system with coolant to the correct level.