0437205 EVINRUDE CARBURETOR ASSY., 115 models

Start By:a. remove fuel linesb. remove fuel filter base 1. Remove nuts (2) and cover (1) from the timing gear cover. 2. Loosen bolt (3). Leave a gap of 3.2 mm (.125 in.) between the washer and the gear. 3. Use tool (A) to remove gear (4). 4. Remove the nut and disconnect cable assembly (5) from the governor control lever.5. Remove the bolts and disconnect bracket assembly (6) from the governor. 6. Disconnect pressure line (7) at the fuel ratio control.7. Put a mark on wires (9) and disconnect them from the fuel shutoff solenoid.8. Disconnect wires (8) from the alternator. 9. Remove clamps (11) and tube assemblies (10) and (12) from the engine. 10. Remove the bolt and disconnect clip (16).11. Disconnect tube assemblies (13) and (14) and hose (15). 12. Remove bolts (18) and nuts (17) that hold the fuel injection pump and governor in place. 13. Remove nut (19), the bolt (other side not shown) and heat shield (20) from the engine. 14. Fasten a strap and hoist to fuel injection pump housing and governor (21) as shown.15. Pull drain line (22) from the clip on the engine block.16. Remove fuel injection pump housing and governor (21). The weight of the fuel injection pump housing and governor is approximately 26 Kg (58 lb.).Install Fuel Injection Pump Housing And Governor (Earlier)
1. Put O-ring seals (23) and (24) in position on the fuel injection pump housing and governor. Put clean oil on the O-ring seals. 2. Put the fuel injection pump housing and governor in position on the oil manifold and the timing gear plate with bolts (18) and nuts (17).3. Put drain line (22) into position on the clip on the engine block.
After the fuel injection pump housing and governor are installed on the timing gear plate, be sure the rack is free to move. The O-ring seal (23) on the drive end of the fuel injection pump can hold the rack and prevent free movement of the rack. If the rack does not move freely, remove the fuel injection pump housing and governor and check the O-ring seal on the drive end of the fuel injection pump housing.
4. Install heat shield (20) between the manifold and fuel injection pump housing and governor. Tighten the bolt to a torque of 23 4 N m (17 3 lb.ft.).5. Connect tube assemblies (13) and (14) and hose assembly (15) as shown.6. Install bolt and clip (16). 7. Install tube assemblies (10) and (12) to the engine and clip (11) that holds them together. 8. Connect wire assemblies (8) to the alternator.9. Connect wires (9) to the fuel shutoff solenoid.10. Connect pressure line (7) to the fuel ratio control. 11. Connect bracket (6) to the governor.12. Connect cable assembly (5) to the governor control lever. 13. Use the following procedure to put the No. 1 piston at top center on the compression stroke. No. 1 piston at top center (TC) on the compression stroke is the starting point for all timing procedures.a. Loosen hose clamps (26), bolt (25) and remove the breather from the valve cover. b. Remove the plug from the flywheel housing.c. Turn the crankshaft clockwise (as seen from the front of the engine) until a 3/8"-16 NC bolt (27) at least 2.5 in. long can be installed in the flywheel through the hole in the flywheel housing. Do not turn the crankshaft counterclockwise. The rocker arms for No. 1 piston can be seen through the breather hole in the valve cover.d. Check