5007398 EVINRUDE CYLINDER/CRANKCASE Assy

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 9U-6198 Crankshaft Turning Tool 1
A(2) 5P-7306 Housing 1
5P-7305 Engine Turning Tool 1
B 136-4632 Timing Pin
(Crankshaft) 1
268-1966 Adapter
C 364-9107 Timing Pin
(Fuel Injection Pump) 1
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High-Pressure Fuel Lines" for safety information.Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Illustration 1 g06188039
Illustration 2 g06187954
Illustration 3 g06188533
If necessary, use Tooling (A) to rotate the crankshaft so that number one piston is at top dead center. Refer to System Operation, Testing and Adjusting, "Fuel Injection Timing - Check" for the correct procedure.
Install Tooling (B) into Position (Y) to lock the crankshaft so that number one piston is at top dead center.
Install Tooling (C) into Position (X) to lock fuel injection pump (13) in the correct position. Refer to System Operation, Testing and Adjusting, "Fuel Injection Timing - Check" for the correct procedure.
If necessary, install studs (15) to front housing (17). Tighten the studs to a torque of 11 N m (97 lb in).
Position a new gasket (18) (not shown) onto front housing (17).
Carefully install fuel injection pump (1) to front housing (17). Ensure that the front housing is not damaged as the fuel injection pump is installed.Note: The fuel injection pump should be supported by hand as the nuts and bolts are installed.
Install nuts (16) to the fuel injection pump finger tight.
Install new bolts (19) to the fuel injection pump. Ensure that the different length bolts are installed in the correct positions.
Tighten bolts (19) to a torque of 22 N m (195 lb in).Tighten nut (16) to a torque of 22 N m (195 lb in).
Remove Tooling (C) from Position (X) on the fuel injection pump . Install a new O-ring seal (11) (not shown) to plug (12).
Install plug (12) to fuel injection pump (1). Tighten the plug to a torque of 14 N m (124 lb in).
Remove the appropriate caps to install fuel injection line (13). Install a new fuel injection line (13) to the fuel injection pump and to the fuel manifold. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure.
Remove the appropriate plugs and caps to install plastic tube assembly (4) and plastic tube assembly (14) to fuel injection pump (13).
Connect plastic tube assembly (4) and plastic tube assembly (14) to the fuel injection pump.
Position bracket (3) onto the cylinder head and install bolt (2) to the bracket. Tighten the bolt to a torque of 5 N m (44 lb in).
Secure plastic tube assembly (4) to the tube clip that is installed to bracket (3).
Connect harness assembly (5) to flow control valve (6).
Connect harness assembly (7) to fuel temperature sensor (10).
Connect harness assembly (8) to the engine oil pressure sensor (9).
Remove Tooling (B) from the cylinder block.
Install a new O-ring seal (21) to plug (20). Install the plug into the cylinder block in Position (Y). Tighten the plug to a torque of 21 N m (186 lb in).
Turn the fuel supply to the ON position.
Turn the battery disconnect switch to the ON position.
Install crankcase breather canister and plastic tube assemblies. Refer to Disassembly and Assembly, "Crankcase Breather - Install" for the correct procedure.
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.
After replacement of the fuel injection pump, the fuel injection pump must be calibrated. Use the electronic service tool to perform "High Pressure Fuel Pump Calibration".