0435093 EVINRUDE ENGINE COVER ASSY., 90

Start By:a. remove timing gear cover1. Put the engine in correct timing. See the topic, Remove Fuel Injection Pump Housing and Governor (Earlier) or Remove Fuel Injection Pump Housing And Governor (Later) for this procedure.
Typical Example2. Remove bolt (1) and the washer that holds gear (2) in place.3. Install tooling (C) and bolt (1) to hold the sleeve on the end of the fuel injection pump camshaft.4. Install tooling (A) on gear (2) and tighten the center bolt of tooling (A) until the gear is loosened.5. Remove tooling (A), bolt (1), tooling (C) and the gear.
Typical Example6. Remove bolts (4), plate (3) and idler gear (5). 7. Inspect the bearing in idler gear (5) for wear or damage. If a replacement of the bearing is needed, use tool group (B) and a press to remove it from the gear as shown.
Typical Example8. Remove bolts (6) and camshaft gear (7) from the camshaft.9. Remove the three nuts on the back side of the plate that hold the fuel pump to the plate.
Typical Example10. Bend locks (9) away from the bolts.11. Remove the bolts, locks (9) and plate (8) from the cylinder block.12. Remove the old gasket material from the cylinder block and plate (8).Install Timing Gears And Plate
Typical Example1. Make sure O-ring seal (10) is in place on the fuel pump housing.2. Clean the old gasket from the contact surfaces of the timing gear plate and cylinder block. Install a new gasket on the cylinder block. Cut the gasket even with the bottom face of the cylinder block. Put 5H2471 Gasket Cement on the bottom of the gasket where the gasket makes contact with the gasket for the oil pan.
Typical Example3. Put timing gear plate (8) in position on the cylinder block. Install the three nuts that hold the fuel pump on the back side of the timing gear plate. Install locks (9) and the six bolts that hold the plate in place.
Typical Example4. Install camshaft gear (7) with the "C" mark on the camshaft gear in alignment with the "C" mark on the crankshaft gear. Install the washers and bolts (6) that hold the camshaft gear in place. 5. Install the bearing in idler gear (5) with tool group (B) and a press. The end of the bearing must be 1.52 mm (.060 in.) below the face of the gear hub.
Typical Example6. Put idler gear (5) in position, and install plate (3) and bolts (4) that hold it.
Typical Example7. Put fuel injection pump drive gear (2) in position on the fuel injection pump, and install the bolt and washer that hold it. Install the washer with the larger outside diameter toward the bolt head. Do not tighten the bolt at this time. 8. Install tooling (D) in the holes of the fuel injection pump drive gear as shown. Put a torque of approximately 68 N m (50 lb.ft.) on the pump drive gear in a clockwise direction (as seen from the front of the engine). With the clockwise torque on the pump drive, use tooling (E) to tighten the bolt to a torque of 270 25 N m (200 18 lb.ft.).9. Check timing of the fuel injection pump and engine, see the topic, Timing Check in the Systems Operation, Testing And Adjusting Manual.End By:a. install timing gear cover