0435678 EVINRUDE CARB, REPAIR KIT

START BY:a. remove air cleaner housingb. remove exhaust manifoldc. remove fuel injection nozzles**The fuel injection nozzles do not have to be removed from the cylinder head assembly when the cylinder head assembly is removed from the cylinder block. If the fuel injection nozzles are not removed, do not put the cylinder head assembly down on a flat surface. This can cause damage to the fuel injection nozzles.1. Drain the coolant from the cooling system. 2. Remove four bolts (2) that hold elbow (air inlet) (1) and bracket assembly (3) to the cylinder head assembly. 3. Remove water outlet tube (5) from the air compressor and the cylinder head assembly.4. Remove air inlet tube (6) from the air compressor and the cylinder head assembly.5. Put identification marks on wires (4), and disconnect them from the sending unit.6. Loosen hose clamp (10) that holds the hose to elbow (8).7. Remove two bolts (7) that hold elbow (8) to the cylinder head assembly.8. Remove two bolts (9) that hold elbow (8) to the water pump, and remove the elbow from the water pump and cylinder head assembly.9. Remove the water temperature regulator. See Water Temperature Regulator.10. Remove the rocker shaft assembly and push rods. See Rocker Shaft Assembly And Push Rods.
Typical Example It may be necessary to remove the rear lifting bracket from the cylinder head assembly to remove the left rear cylinder head bolt.11. Remove all bolts (11) and (12) that hold the cylinder head assembly to the cylinder block.
Typical Example12. Install tooling (A) and a hoist on cylinder head assembly (13), and remove the cylinder head assembly and gasket from the engine. The weight of the cylinder head assembly is approximately 68 kg (150 lb.).
Typical Example13. Remove water seals (14) and O-ring seal (15) from the spacer plate.
Do not damage the dowels as the spacer plate is removed.
14. Remove spacer plate (16). 15. Remove O-ring seal (18) and spacer plate gasket (17) from the cylinder block.Install Cylinder Head Assembly And Spacer Plate
When the cylinder head assembly is removed, a new spacer plate gasket and a new cylinder head gasket must be installed. Do not use any adhesive or other substances on these gaskets or the surfaces they contact.
1. Thoroughly clean the spacer plate, cylinder head assembly and cylinder block surfaces. If dowel (2) was removed for any reason, install a new dowel until it extends 16.0 0.5 mm (.63 .02 in.) from the cylinder block.2. Install a new spacer plate gasket (3).3. Install a new O-ring seal (1) on dowel (2) against the cylinder block. Both surfaces of the spacer plate, the top of the cylinder block and both sides of the spacer plate gasket must be clean and dry. Do not use any gasket adhesive or other substance on these surfaces.4. Install spacer plate (7).5. Check the cylinder liner projection weight. See Install Cylinder Liners.6. Install a new O-ring seal on top of the spacer plate around dowel (6).7. Install new water seals (5) in the spacer plate. 8. Install a new, dry gasket (9) on the cylinder block.9. Install tooling (A) on cylinder head assembly (8) as shown, and fasten a hoist to it. Put the cylinder head assembly in position on the cylinder block.10. Put 2P2506 Thread Lubricant on all of the cylinder head bolts, and install them until they are finger tight. Remove tooling (A) from the cylinder head assembly. 11. Install push rods (11). Make sure they are installed in their original locations. Be sure the push rods are in position in the valve lifters.12. Loosen the adjusting screws on the rocker arms for adjusting valve clearance. This will prevent a bent valve or push rod during installation of the rocker shaft assembly.13. Install a new O-ring seal in the rear rocker arm support bracket.14. Put 2P2506 Thread Lubricant on all of the rocker shaft bolts except the one that goes through the rear rocker arm support bracket.15. Put rocker shaft assembly (10) in position on the cylinder head assembly. Make sure the dowels in the support brackets are in the dowel holes in the cylinder head assembly and the rocker arms are engaged with the push rods. Install the bolts that hold the rocker shaft assembly until they are finger tight. 16. Hand tighten the large size cylinder head and rocker shaft bolts in the numbered sequence shown.a. Tighten the bolts in the numbered sequence to a torque of 156 N m (115 lb.ft.).b. Tighten the bolts in the numbered sequence to a torque of 250 17 N m (185 13 lb.ft.).c. Tighten the bolts in the numbered sequence to a torque of 250 17 N m (185 13 lb.ft.).17. Hand tighten the small size cylinder head bolts, in the lettered sequence shown for each engine to a torque of 43 7 N m (32 5 lb.ft.).18. See Valve Clearance in Testing And Adjusting, and make an adjustment to the valves. The intake valves must have a clearance of 0.38 mm (.015 in.). The exhaust valves must have a clearance of 0.64 mm (.025 in.).19. If the rear lifting bracket was removed, put the bracket in position on the cylinder head assembly, and install the two bolts that hold it in place.20. Install the valve cover. See Valve Cover.21. Install the water temperature regulator. See Water Temperature Regulator. 22. Inspect the two gaskets for water pump elbow (16), and make a replacement if necessary.23. Put elbow (16) in position on water pump, cylinder head assembly and in the water inlet pipe hose.24. Install two bolts (14) that hold the elbow to the cylinder head assembly.25. Install two bolts (17) that hold the elbow to the water pump.26. Tighten hose clamp (18) that holds the hose to elbow (16).27. Connect wires (12) in their original location on the sending unit.28. Install air inlet tube (15) to the air compressor and the cylinder head assembly.29. Install water outlet tube (13) to the air compressor and the cylinder