0114996 EVINRUDE O-RING, Gearcase head

Removal
IMPORTANT: Never steam clean or pour cold water on an injection pump while the pump is running or while it is warm.Clean the injection pump, lines, and area around the pump with cleaning solvent or a steam cleaner.
Fig. 1-Timing MarkUse JD-281 or JDE-81-1 Flywheel Turning Tool to position number one piston at top dead center. When the timing pin is inserted in the hole in the flywheel and the timing mark (A, Fig. 1) is visible on the injection pump governor weight retainer, the number one piston is at top dead center on the compression stroke.3-179D Engine (ROTO-DIESEL Fuel Injection Pump)
Fuel Injection Pump Only
Escaping diesel fuel under pressure can have sufficient force to penetrate the skin causing serious personal injury.If injured by escaping fuel, see a doctor at once. Serious infection or reaction can develop if proper medical treatment is not administered immediatetly.
Fig. 2-Loosen Injection Lines at NozzlesTo relieve high pressure in the fuel system, slightly loosen fuel injection line connections at each injection nozzle with two wrenches (Fig. 2).
Fig. 3-ROTO-DIESEL Fuel Injection Pump RemovalDisconnect throttle linkage (B, Fig. 3) and electric shut-off wire (C).Disconnect fuel return line (A) and fuel supply line (D). IMPORTANT: When removing injection lines, DO NOT turn pump outlet fittings. Turning these fittings may damage pump internally.Disconnect injection lines (E).Close all openings with caps and plugs.Remove injection pump gear cover from timing cover.Remove drive gear attaching nut from injection pump shaft and spring washer.
Fig. 4-Fuel Injection Pump Removal 1 -Nut2 -Cap Screw3 -Cap ScrewAttach special took KJD-10108 to timing gear housing (Fig. 4).Remove three hex nuts (F, Fig. 3).Turn cap screw of special tool clockwise until pump shaft is loosened from drive gear. When removing fuel injection pump, be careful not to lose pump shaft Woodruff key.Remove fuel injection pump.Remove special tool KJD-0108.3-164D, 4-219D, 4-239D, 4-276D, 6-329D or 6-359D Engine (ROOSA-MASTER Model JDB)
Fuel Injection Pump OnlyPosition crankshaft so that number one piston is at top dead center on compression stroke.
Escaping diesel fuel under pressure can have sufficient force to penetrate the skin causing serious personal injury.If injured by escaping fuel, see a doctor at once. Serious infection or reaction can develop if proper medical treatment is not administered immediately.
Fig. 5-Loosen Injection Lines at NozzlesTo relieve high pressure in the fuel system, slightly loosen fuel injection line connections at each injection nozzle with two wrenches (Fig. 5).
Fig. 6-Fuel Injection Pump RemovalDisconnect fuel supply line (1, Fig. 6), fuel return line (2), and fuel injection lines (3). Plug or cap all openings.Disconnect throttle linkage and wire throttle lever (4) in high idle position.Remove nuts (5) attaching injection pump to engine front plate.Slide pump in a straight line away from the front plate.Injection pump drive gear and shaft will remain on front plate. Injection Pump Drive ShaftRemove injection pump (Group 0413).Remove injection pump gear cover.
Fig. 7-Drive Shaft RemovalRemove thrust pin (1, Fig. 7) and thrust spring.Remove nut (2) from the end of the drive shaft.
Fig. 8-JD303-Injection Pump Shaft Removal ToolInstall JD303 Injection Pump Shaft Removal Tool (Fig. 8) on timing gear cover. Tighten attaching cap screws securely. IMPORTANT: Do not overtighten center cap screw.Turn center cap screw clockwise against the injection pump drive shaft until the drive gear is held firmly against the front plate.Make a tubular type driver. See Group 0499 "Special Tools (0413)".
Fig. 9-DriverHold driver (Fig. 9) over injection pump drive shaft against injection pump gear. Use a medium weight hammer (12 oz. [340 g.]) to hit the end of the driver.If injection pump drive shaft does not come out of injection pump gear after several hits, hold a heavy bar or hammer against JD303 tool center screw. Hit driver harder several times.If injection pump drive shaft still does not come out of injection pump gear after several more hits, remove injection pump drive gear and shaft (Group 0413). Injection Pump Drive Gear and ShaftRemove timing gear cover (Group 0402).
Fig. 10-JD254 Timing ToolUsing JD-254 Timing Tool, check to see that drive gear timing marks align with timing tool (Fig. 10).Slide drive gear and shaft forward to remove them.4-239T, 4-276T, 6-359T, 6-414D, or 6-414T Engine (ROOSA-MASTER Model DM)
Fig. 11-19918 Timing WindowRemove timing hole cover and install 19918 Timing Window on injection pump.Rotate crankshaft to position number one piston at top dead center on compression stroke. The timing marks on the governor weight retainer and cam ring should align.
Escaping diesel fuel under pressure can have sufficient force to penetrate the skin causing serious personal injury.If injured by escaping fuel, see a doctor at once. Serious infection or reaction can develop if proper medical treatment is not administered immediately.
Fig. 12-Loosen Injection Lines at NozzlesTo relieve high pressure in the fuel system, slightly loosen fuel injection line connectors at each injection nozzle.
Fig. 13-Fuel Injection Pump RemovalDisconnect throttle linkage (1, Fig. 13).Disconnect fuel supply line (2) and fuel return line (3). IMPORTANT: When removing injection lines, do not turn pump outlet fittings. Turning these fittings may damage pump internally.Using two wrenches, disconnect injection lines (4).Plug or cap all openings.Remove injection pump gear cover from timing gear cover.
Fig. 14-Drive Gear NutRemove drive gear nut (1, Fig. 14).Remove injection pump attaching nuts (2) and remove injection pump from front plate.Repair
3-179D Engine
ROTO-DIESEL Fuel Injection PumpDo not disassemble the Roto-Diesel fuel injection pump further than necessary for installing available parts, not even for cleaning.Proper checking of the fuel injection pump, especially as regards deliveries in various load ranges and the operation of the governor, is only possible if a special test stand and the appropriate specifications are available. Therefore, take a faulty pump to your local Roto Diesel service center.Pressurizing Valves
Fig. 15-Pressurizing Valve 1 -Valve Body2 -Pressure Spring3 -Valve Piston4 -Plug Pressurizing valves (see Fig. 15) are only available as an assembly, they cannot be disassembled.Remove pressurizing valve assembly from injection pump head.If leakage occurs at the connection of pressurizing valve and fuel pressure line on pump head, remove pressurizing valve from pump head and replace both sealing washers.Remove and replace a defective