5007663 EVINRUDE *GEAR SET, Fwd, Pinion

start by: a) remove fuel injection lines 1. Remove cover (1) from the front of the timing gear cover. Remove bolt (2) and washer (3). Install bolt (2) again to the position shown. Use tool (A) to loosen the pump drive gear from the camshaft. Remove tool (A) and bolt (2).2. Remove the governor linkage. Disconnect the fuel supply line. 3. Remove inlet oil tube (4) for the turbocharger.4. Disconnect the air tube from the fuel ratio control.5. Disconnect hose (5).6. Disconnect the three drain tubes from the fuel injection pump housing.7. Remove bracket (6).8. Remove the three nuts that hold the fuel injection pump housing and governor to the timing plate.9. Remove the fuel injection pump housing and governor.Install Fuel Injection Pump Housing And Governor
1. Use the following procedures to put the No. 1 piston at top center on the compression stroke. No. 1 piston at top center (TC) on the compression stroke is the starting point for all timing procedures. The engine is seen from the flywheel end when direction of flywheel rotation is given.a) Turn the flywheel approximately 30 degrees clockwise. The reason for making this step is to be sure the play is removed from the timing gears when the engine is put on top center. b) For engines with a timing pointer, remove the cover on the flywheel housing. Turn the flywheel counterclockwise until the "TC 1" mark on the flywheel is in alignment with the pointer.c) For engines with a timing bolt, turn the flywheel counterclockwise until a 3/8-16 NC bolt can be installed in the flywheel through the hole in the flywheel housing. Do not turn the flywheel backwards.d) Remove the breather from the valve cover. The rocker arms for No. 1 piston can be seen through the breather hole in the valve cover.e) Check to see if both rocker arms for the No. 1 piston can be moved backward and forward by hand. The No. 1 piston is at top center on the compression stroke when the "TC 1" mark on the flywheel is in alignment with the pointer, or the bolt can be put in the flywheel through the hole in the flywheel housing, and both rocker arms for the No. 1 piston can be moved backward and forward by hand. f) If both rocker arms can not be moved by hand, the No. 1 piston is not at top center on the compression stroke. Turn the flywheel counterclockwise one full turn (360°). For engines with a timing pointer, the "TC 1" mark on the flywheel must then be in alignment with the pointer. For engines with a timing bolt, the bolt must be installed in the flywheel through the hole in the flywheel housing.2. For engines with a timing pointer, turn the flywheel counterclockwise until the pointer is between the 1° and 2° mark on the flywheel as shown. 3. For engines with a timing bolt, do not turn the flywheel past this position. 4. Remove the bolt from cover (2) and install timing pin (1) in the groove (slot) of the fuel injection pump camshaft.5. Inspect the O-ring seal for the fuel transfer pump. Install a new seal if needed. Put clean engine oil on the seal.6. Put the fuel injection pump housing and governor in position on the engine. Install the three nuts that hold the housing in place. 7. Install washer (3) and bolt (4). Bolt (4) holds the pump drive gear to the camshaft. Tighten the bolt to a torque of 110 5 lb. ft. (149 7 N m).8. Use the following procedure to make sure the timing of the engine is correct: a) Remove the timing pin from the pump housing.b) Turn the flywheel counterclockwise approximately 1/2 turn (180°). Install the timing pin in the pump housing again.c) While turning the flywheel counterclockwise push on the timing pin until it slides into the groove (slot) in the pump camshaft.d) Note the position of the flywheel. The timing of the engine is correct when the pointer is between the 1° and 2° mark on the flywheel, or the timing bolt can be installed in the flywheel through the hole in the flywheel housing and the timing pin is installed in the groove (slot of the fuel injection pump camshaft.e) Remove the timing pin from the pump housing. Install the bolt in the cover on the pump housing. If the timing of the engine is not correct, the fuel injection pump housing and governor must be removed and installed again. 9. Install cover (5). 10. Install bracket (6).11. Connect hose (7), the three drain tubes and the fuel supply line to the fuel injection pump housing.12. Connect the air tube to the fuel ratio control.13. Install the inlet oil tube for the turbocharger. Install the governor linkage.end by: a) install fuel injection linesb) make adjustment of the fuel system setting (See Fuel System Setting in Testing and Adjusting)