0386903 EVINRUDE COVER ASSY.

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
B     130-6993     Injector Seat Cleaning Brush     1    
C     5P-0329     Wrench (1)     1    
D     4C-6774     Vacuum Gun Kit     1    
E     5P-0960     Grease Cartridge     -    
( 1 ) The wrench is part of the 9U-5106 Diesel Engine Tool Group .
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Remove the protective plug in the unit injector opening. Carefully insert a screwdriver with a long blade through the unit injector opening until the screwdriver contacts the top of the piston. Withdraw the screwdriver, and check for the presence of fuel or engine oil on top of the piston. If present, use an oil sampling vacuum withdraw pump in order to remove the accumulation. Large liquid accumulation can cause a hydraulic lock and engine damage.
Note: It is very important to clean the cylinder head bore for the injector before you install the injector.
Use Tooling (B) with a drill in order to clean the cylinder head bore for the fuel injector. Clean the bore until the surface is smooth and shiny.Note: Tooling (D) is recommended for cleaning loose particles from the bore. The vacuum is operated with pressurized air.Use Tooling (D) in order to remove all of the loose particles from the bore.
Apply Tooling (E) to the entire cylinder head bore for the fuel injector.
Do not adjust the trim screw on the unit injector. The trim screw helps control the amount of fuel that is delivered. If the trim screw is moved, the fuel will not be delivered correctly. If the trim screw is loose, the unit injector must be replaced.
Do not let the tip of the unit injector contact any components. Damage to the tip will make replacement of the unit injector necessary.
Illustration 1 g01213696
Illustration 2 g00644650
Dowels on the injector
Illustration 3 g00644646
Bolt for the fuel rack lever
Lubricate the bores for new O-ring seals (9) and (10) with Tooling (E). Install the O-ring seals on fuel injector (7) .
If necessary, install studs (8). Tighten the studs to a torque of 50 5 N m (37 4 lb ft).
Carefully place fuel injector (7) into the cylinder head.
Make sure that the dowels on the fuel injector are around the bridge dowel.
Make sure that the round end of the bolt for the fuel rack lever is in the notch in the fuel rack.
Do not tap on the top of the unit injector in order to seat the unit injector in the bore. Damage to the tip can occur. This will make replacement of the unit injector necessary.
Note: Make sure that the top surface of clamp (6) is parallel to the top surface of the cylinder head within 2.0 mm (0.08 inch).
If the clamp is not centered around the injector spring, contact between the spring and the clamp can occur when the engine is running. This could result in broken injector springs or hold-down clamp bolts.
Install clamp (6), the washers, and nuts (5). Tighten the nuts evenly in order to seat the injector into position. Tighten the nuts to a torque of 35 5 N m (26 4 lb ft).
Inspect the area between the side of the fuel injector spring and the hold-down clamp. The hold-down clamp must be centered around the fuel injector spring. The distance between the fuel injector spring and the hold-down clamp must be approximately equal around the fuel injector spring.If the hold-down clamp is not centered around the fuel injector spring, remove the nuts that hold the hold-down clamp in place. Rotate the hold-down clamp for 180 degrees ( 1/2 turn) and repeat Steps 5 and 6.
After the nuts are tightened, the fuel rack lever and the fuel rack must move freely.
Synchronize the fuel rack. Refer to Testing and Adjusting, "Fuel Injector Synchronization".
Adjust the fuel injection control linkage. Refer to Testing and Adjusting, "Fuel Control Linkage Adjustment".