5041592 EVINRUDE BOLT

1. Remove the bolts, clamps and service meter (1) from the accessory drive housing. 2. Remove the bolts, stop (3), spacer (2) and the gasket from the accessory drive housing. 3. Install stop (3) without the spacer and the gasket and install two 5/16"-18 NC bolts. 4. Remove bolt (5) and disconnect linkage (4) from the lever on the governor housing. 5. Remove felt washer (6) from the fuel injection pump. 6. Use tooling (A) and remove the bushing from the fuel injection pump. 7. Remove seal (7) from the fuel injection pump. 8. Move lever (9) forward to move the rack to the center position and use tool (B) and remove fuel injection pump (8) from the fuel injection pump housing.Install Fuel Injection Pumps
The fuel rack must be in the center position before the correct installation of an injection pump is possible.
1. Put the groove of barrel (2) in alignment with the slot of the gear segment (the slot is on the opposite side of the gear segment teeth).2. Move lever (3) forward to move the rack to the center position.3. Look inside the bore of the injection pump housing to find the dowel. Put groove of the barrel in alignment with the dowel and put the injection pump straight down into the bore.4. Use tool (A) and install fuel injection pump (1) in the fuel injection pump housing. 5. Inspect for wear or damage and make a replacement if necessary of seal (4).6. Put seal (4) in position on the fuel injection pump. 7. Install bushing (5) that holds the fuel injection pump in the fuel injection housing. If the fuel injection pump is in the correct position, bushing (5) will turn into the fuel injection housing by hand until the top of the bushing is even with the fuel pump housing.8. Use tool (B) and tighten bushing (5) to a torque of 200 13 N m (150 10 lb.ft.). 9. Put felt washer (6) in position on the fuel injection pump.10. After each pump has been installed, check total rack travel to make sure each pump has been installed correctly. See TESTING AND ADJUSTING. 11. Connect linkage (7) to the lever on the governor housing. 12. Remove stop (8) from the accessory drive housing. 13. Install spacer (9), the gasket and stop (8) on the accessory drive housing. 14. Install service meter (10), the clamps and the bolts on the accessory drive housing.END BY:a) install fuel linesDisassemble Fuel Injection Pumps
START BY:a) remove fuel injection pumps
Be careful when the injection pumps are disassembled. Do not damage the surfaces of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.
1. Pull plunger (7), washer (6) and spring (5) out of barrel (4).2. Remove washer (6) from plunger (7).
Do not remove the gear from the plunger. The gear and plunger are assembled and adjusted at the factory.
3. Remove ring (3) and make a separation of barrel (4) from bonnet (1).4. Remove check valve (9), seat (8) and spring (2) from bonnet (1). If the check valve assembly is disassembled, do not mix the parts with parts from another check assembly.Assemble Fuel Injection Pumps
Put clean fuel oil on all parts during assembly.
1. Put spring (7), seat (9) and check valve (5) into position in bonnet (8).2. Install bonnet (8) on barrel (4) and install ring (6) to hold them together. Do not slide bonnet (8) across barrel (4) because the check valve assembly in the bonnet can cause damage to the face of barrel (4).3. Install spring (3) on barrel (4).4. Install washer (2) on plunger (1) with the flat side toward the gear on the plunger.5. Install plunger (1) in barrel (4) until washer (2) is engaged in the spring.END BY:a) install fuel injection pumps