0912082 EVINRUDE END CAP, Cylinder

Table 1
Required Tools
Tool Part Number Part Description Qty
A 5F-4764 Pry Bar 1
B 130-6993 Injector Seat Cleaning Brush 1
C 5P-0960 Grease Cartridge - Start By:
Remove the rocker shaft and pushrod.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Personal injury or death can result from the engine starting.The engine can start and injure persons working on or near the engine.Be sure the engine cannot be started while service work is being performed. This is very important when the engine is equipped with an Automatic Start Stop System.On engines equipped with an air starting system, close the air supply valve to the air starting motor before service work is begun.
Turn OFF the fuel supply to the engine.
Illustration 1 g03743677
Be sure to drain the fuel system in order to avoid the introduction of fuel into the cylinders or cause fuel to flow over the engine when the tubes are removed
Remove plug (1) in order to drain the cylinder head of fuel that is on the unit injectors.
Illustration 2 g03744363
Disconnect fuel supply tube assembly (3) at the fuel supply manifold.
Introduce clean pressurized air that is regulated to 207 kPa (30 psi) into fuel return tube assembly (2) through fuel supply tube assembly (3). This is done in order to purge fuel from the cylinder head into the fuel return manifold.
Remove fuel supply tube assembly (3) and fuel return tube assembly (2). Plug or cap all of the openings.
Illustration 3 g01299027
Remove bolt (4) and unit injector clamp (5).
Use Tooling (A) in order to pry on fuel injector (6). This will loosen the fuel injector in the bore.
Carefully remove fuel injector (6) from the cylinder head. Put identification on the fuel injector in order to identify the cylinder head.
Install a plastic plug in the fuel injector opening in the cylinder head. Note: Put a clean cover over the cylinder head in order to prevent the entry of airborne dust or abrasive particles into the engine.Installation Procedure
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.
Illustration 4 g01299027
Install new seals on fuel injector (6).
Apply clean engine oil to the seals.
Use Tooling (B) and use a hand drill in order to clean the bore for the fuel injector in the cylinder head. Note: Apply Tooling (C) to the bore of the cylinder head for lubrication of the O-ring seals. Tooling (C) should run the entire length of the bore.
Do not let the tip of the unit injector contact any components. Damage to the tip will make replacement of the unit injector necessary.
Carefully place fuel injector (6) into the cylinder head.
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.
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 unit injector clamp (5), the washer, and bolt (4). Tighten the bolt to a torque of 215 40 N m (160 30 lb ft). Use bolt (4) and unit injector clamp (5) to pull the fuel injector into position.
Inspect the area between the side of the fuel injector s