0388002 EVINRUDE GEARCASE,Bearing & seal assembly

Illustration 1 g00867065
Tools that are required in order to measure the air pressure during the calibration of the wastegate actuator (A) Air pressure regulator (B) Air pressure gauge (C) Tee or cross (D) Hose barb coupler (E) Valve for use with cross (F) Valve (G) Fitting for connection to the air supply (H) Test hose 161-6960 (J) 161-6963 Clamps (Hose)The following part will be required in order to replace the wastegate actuator, if necessary.
A 225-0319 Actuator Kit A crimping tool 213-4269 will also be required at final installation.
Inspect the lines for the wastegate solenoid for any signs of damage. Repair the damage as it is necessary.
Disconnect the hose from the wastegate diaphragm.
Apply 138.1 kPa (20.03 psi) of air to the wastegate diaphragm.
Observe the movement of the dial indicator needle. The measurement of the movement of the actuator rod should be 1.0 mm (0.039 inch).Note: Inspect the wastegate for damage if the wastegate is not within specifications. Replace the wastegate if the movement of the actuator rod is not within specifications.Determine the Actuation Calibration Reading
Allow the turbocharger to cool.
Illustration 2 g00918362
Install dial indicator (1) on the engine. The travel of the dial indicator must align with the travel of the rod (2) or an error in the measurement will occur. Refer to Illustration 2.
Remove the hose (4) from the actuator (3) .
Illustration 3 g00918469
Connect the air supply to the air pressure regulator (A) .
Connect the test hose (H) to the actuator (3) with hose clamps (J) .
Turn the knob on air pressure regulator (A) and slowly increase the air pressure while you observe the dial indicator (1). Increase the air pressure until the travel of the rod (2) is 1.00 mm (0.039 inch). Observe the pressure gauge (B) and record the pressure reading.
Turn the knob on air regulator (A) and slowly decrease the pressure to 0 kPa (0 psi). Repeat Step 6. Observe the pressure gauge (B) and record the pressure reading.
This pressure reading is the Actuator Calibration Reading.The Actuation Calibration Reading is Above 128 kPa (18.5 psi)
No further action is necessary if the actuator calibration reading is above 128 kPa (18.5 psi). Remove the test hose and all test equipment. Install the hose for the actuator. Be sure that the hose is not kinked. Be sure that the hose does not rub at any point. Continue with an alternate diagnosis.The Actuation Calibration Reading is Below 103 kPa (15 psi)
The turbine housing must be replaced if the actuation calibration reading is below 103 kPa (15 psi). Remove the test hose and all test equipment and replace the turbine housing. Refer to Disassembly and Assembly, "Turbocharger - Disassemble" and Disassembly and Assembly, "Turbocharger - Assemble".The Actuation Calibration Reading is Between 103 kPa (15 psi) and 128 kPa (18.5 psi)
The actuator must be replaced and recalibrated if the actuation calibration reading is between 128 kPa (18.5 psi) and 103 kPa (15 psi). Replace the wastegate actuator with a 225-0319 Actuator Kit. Refer to "Installation and Calibration of a New Wastegate Actuator".Installation and Calibration of a New Wastegate Actuator
Use the following procedures in order to install a 225-0319 Actuator Kit and calibrate the new wastegate actuator.
Illustration 4 g00918562
Apply 138 kPa (20 psi) of air pressure to the actuator (3). Remove the clip (5) from the crank pin. Discard the clip (5) .
Reduce the air pressure to 0 kPa (0 psi) and remove the test hose (H) from the actuator (3) .
Illustration 5 g00918611
Note the orientation of the hose nipple (6) on the actuator (3). Remove the nuts (7) that fasten the actuator to the bracket and remove the actuator. Do not remove the bracket.
Illustration 6 g00918624
(8) New actuator (9) Nut (10) Jam nut (11) Rod end (12) Clip
Illustration 7 g00918625
(X) Same length as the old actuator
Refer to Illustration 6 and Illustration 7. Assemble the new actuator (8), jam nut (10), and rod end (11) that is included in the 225-0319 Actuator Kit .