0340778 EVINRUDE COVER, Exhaust hsg., front

1. Disconnect fuel lines (1). Disconnect the fuel pressure switch and remove drive gear cover (2). 2. Remove four capscrews (3) and remove drive gear (4). 3. Disconnect fuel supply and return hoses, injector lines, control linkage and air line. 4. Fasten a hoist and remove all nuts and bolts mounting fuel injector pump housing to engine.Install Fuel Injection Pump Housing And Governor
1. Fasten a hoist to the fuel injection pump housing and governor. Be sure the O-ring seals are in position on the fuel injection pump housing and governor, on the timing gear housing. 2. Connect fuel supply and return hoses, injector lines, control linkage and air line. 3. Remove plug (5) from the fuel injection pump housing. 4. Turn the fuel injection pump camshaft until tooling (B), the timing pin, goes into the slot in the fuel injection pump camshaft. 5. Put the No. 1 piston at top center on the compression stroke. Make reference to Finding Top Center Compression Position for No. 1 Piston in Testing and Adjusting. Use tooling (A) to rotate engine crankshaft counter clockwise (the direction of engine rotation) until the timing bolt (6) can be installed into flywheel. 6. Position the fuel injection pump drive gear onto the end of the fuel injection pump camshaft. To make the installation easier, use two guide studs. Install capscrews (3). Tighten capscrews to a torque of 3 N m (27 lb in).7. Remove timing bolt (6) from the flywheel. Remove the timing pin, tooling (B), from the fuel injection pump. Use tooling (A) and turn the flywheel clockwise (opposite the direction of engine rotation) a minimum of 45 degrees. The reason for this step is to remove backlash from the timing gears when the engine is put on top center (TC).8. Position tooling (B) in the fuel injection pump. Turn the flywheel slowly in the direction of engine rotation until tooling (B), the timing pin, will go into the slot in the fuel injection pump camshaft. Rotate the engine until the fuel pump camshaft is tight against tool (B). This removes gear clearance from the drive train.
Too much pressure on the timing pin can cause damage to the fuel injection pump or the timing pin.
9. If timing bolt (6) can be installed in the timing hole of the flywheel, the timing of the fuel injection pump is correct.10. If the timing bolt does not go into the timing hole in the flywheel, the timing is not correct. Do the steps that follow to adjust the fuel injection pump timing. a. Loosen four bolts (7). With tool (B) installed and the timing bolt removed, turn the flywheel clockwise (opposite the direction of engine rotation) a minimum of 45 degrees. The reason for this step is to remove backlash from the timing gears when the engine is put on top center (TC).b. Tighten two bolts (7) 180 degrees apart, evenly to a torque of 3 N m (27 lb in).c. Turn the flywheel slowly in the direction of engine rotation until the timing bolt can be installed in the flywheel. The No. 1 piston of the engine is now at top center (TC).d. Tighten four bolts (7) to a torque of 55 7 N m (41 5 lb ft). Remove the timing bolt from the flywheel and tool (B) from the fuel injection pump housing.11. Turn the flywheel clockwise (opposite the direction of normal engine rotation) a minimum of 45 degrees, turn the flywheel in the direction of engine rotation until tool (B) drops into slot of pump camshaft. Now, turn the flywheel more, in the direction of normal engine rotation, until all gear clearance is removed from the drive train. Check to see that the timing bolt will go into the flywheel.12. If the timing is not correct, do the procedures in Steps 10a through 10d again. 13. If the timing is correct, remove the timing bolt from the flywheel and the timing pin [tool (B)] from the fuel injection pump housing. Install cover (2) and the plug in fuel injection pump housing.14. Connect fuel lines (1) and connect the fuel pressure switch. Open the fuel valve.15. Install the crankcase front guard.16. Install front and rear hood.End By:a. install air compressorDisassemble Fuel Injection Pump Housing
Start By:a. disassemble governorb. remove fuel injection pumps 1. Remove the six lifters from the fuel pump housing.2. Remove rack (1) and camshaft (2) from the fuel pump housing. If necessary, use a soft hammer to push the camshaft out the governor end. 3. Use tooling (A) and remove the three camshaft bearings from the fuel pump housing. 4. Remove rack bearing (4) and the other rack bearing from the fuel pump housing.5. Remove dowel (3) from the fuel pump housing. 6. Remove bolts (6), cover (5) and the gasket from the fuel pump housing.Assemble Fuel Injection Pump Housing
1. Install gasket (7) and cover (5) on the side of the fuel pump housing. 2. Use tooling (B) and install "D" shaped rack bearing into the automatic timing advance side of the fuel pump housing 87.0 0.5 mm (3.42 .02 in) from outside surface (X).3. The inside flat side diameter after assembly must be 11.178 0.050 mm (.440 .002 in) and the inside large diameter must be 12.767 0.058 mm (.503 .002 in). 4. Install dowel (3) in the fuel pump housing 6.0 .05 (.24 .02 in) above the outside surface.5. Use tool group (C) and install the rack bearing into the fuel pump housing 7.16 0.13 mm (.282 .005 in) below the outside surface of the pump housing.6. The inside diameter of the bearing after assembly must be 12.746 0.045 (.502 .002 in). 7. Use tool group (A) and install the three camshaft bearings in the fuel pump housing with the oil holes in the bearings 30 3 degrees from the horizontal center line toward the plugged holes in the fuel pump housing.8. The inside