0435474 EVINRUDE GEARCASE ASSY., Complete

START BY:a. remove fuel injection linesb. remove fuel filter and base Put caps or plugs on all fuel system openings to keep dirt or foreign material out of the fuel system. 1. Remove oil inlet line (1) and oil drain line (2) from the turbocharger. Install plugs in the openings in the turbocharger and cylinder block. 2. Remove six screws (4) and cover (3) from the governor housing. 3. Put identification marks on lever (5) and the governor shaft for assembly purposes. Remove lever (5) and the cable assembly from the shaft as a unit.4. Remove two bolts (7) and governor housing (6) from the governor. 5. Disconnect fuel return hose assembly (8) from the fuel injection pump housing.6. Remove bolt (9) that holds fuel line (10) to the cover.7. Remove fuel lines (10) and (11). 8. Remove bolt (12) and plug (13) from the timing gear cover. 9. Loosen bolt (14) which holds the fuel pump drive gear to the fuel injection pump camshaft a maximum of one turn. 10. Remove three bolts (15) that hold the fuel system to the oil manifold for the engine oil cooler.11. Loosen three nuts (16) that hold the fuel system to the timing gear plate. Loosen the nuts until they are even with the end of the studs.
Tooling (A) must be installed in the position shown so the looks will not damage the water passage in the timing gear cover.
12. Loosen the drive gear from the fuel injection pump camshaft with tooling (A) as follows:a. Install tooling (A) in the position shown, and tighten the locks to hold the tooling in place.b. Turn the extension counterclockwise to loosen the bolt in the fuel injection pump camshaft. As the bolt is loosened, it will push against tooling (A), and push the fuel injection pump camshaft out of the drive gear.c. Remove tooling (A) from the timing gear cover. Remove the bolt and washer from the fuel injection pump camshaft.13. Remove three nuts (16). See illustration C9098P1, and remove the fuel system from the engine. The weight of the fuel system is 22 kg (49 lb.).Install Fuel Injection Pump Housing And Governor
Typical Example1. Install the fuel injection pump housing and governor on tooling (A), or use a suitable vise to hold the unit.2. Remove three bolts (2), cover (1) and the gasket from the fuel injection pump housing.
Typical Example3. Install the bolt and washer used to hold the drive gear to fuel injection pump camshaft (3).4. Install tool (B) in the hole of the fuel injection pump housing. Turn fuel injection pump camshaft (3) until timing pin (B) engages in the notch in the fuel injection pump camshaft. Tool (B) will hold the fuel injection pump camshaft in the correct position to set the fuel injection timing of the engine. 5. Be sure O-ring seals (4) and (5) are in position on the governor and the fuel injection pump housing.
Be extra careful not to damage the O-ring seals when the fuel injection pump housing and governor are installed on the engine.
6. Put fuel system (6) in position on the engine, and install the three nuts which hold it. 7. Check the condition of the threads on bolt (7) which holds the drive gear to the fuel injection pump camshaft. Also, check the threads in the fuel injection pump camshaft. Put clean engine oil on the threads.8. Install bolt (7) and the washer to hold the drive gear to the fuel injection pump camshaft. Tighten the bolt finger tight only. Bolt (7) must be tight enough to hold the gear clearance (backlash) out of the timing gears when the engine is turned. However, the timing gear must be able to turn on the shaft when the engine is turned to put the No. 1 piston on the top center compression position (TDC). 9. Put No. 1 piston at the top center compression position (TDC) with the following procedure:a. Remove plug (8) from the flywheel housing. b. Remove the bolts that hold electric starting motor (9) to the flywheel housing. Remove the electric starting motor so tooling (C) can be installed in the flywheel housing. For further information on removing the electric starting motor, see Electric Starting Motor.c. Put the housing assembly of tooling (C) in position in the flywheel housing, and install three bolts to hold it in place. Use tooling (C) and turn the crankshaft clockwise (as seen from the front of the engine) until a 3/8"-16 × 3 in. (50.8 mm) bolt can be installed through the timing hole in the flywheel housing and into the hole in the flywheel. d. Remove the valve cover from the valve cover base. 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 the top center compression position when the bolt is installed in the flywheel, and both rocker arms for No. 1 piston can be moved backward and forward. If both rocker arms cannot be moved, the No. 1 piston is not at the top center compression position. Remove the bolt from flywheel. Turn the crankshaft clockwise (as seen from the front of the engine) one full turn (360°), and install the bolt again.10. With the timing pin in the notch of the fuel injection pump camshaft and the timing bolt in the flywheel, tighten the bolt which holds the drive gear to the fuel injection pump camshaft to a torque of 175 7 N m (130 5 lb.ft.).11. Check the timing as follows:a. Remove both the timing pin and timing bolt.b. Turn the crankshaft clockwise (as seen from the front of the engine) two full turns, and install the timing pin and bolt again.c. The timing is correct if both the timing pin and timing bolt can be installed at the same time. The timing procedure must be done again if the timing pin and timing bolt cannot be installed at the same time.d.