0435567 EVINRUDE O-RING & SEAL KIT

Start By:a. remove fuel injection lines 1. Remove turbocharger supply and drain lines (1) from the engine.2. Disconnect cable (2) from governor lever. Remove bracket (4) from governor.3. Remove fuel injection lines (3).4. Disconnect fuel line (5) from the fuel injection pump housing. 5. Disconnect tube assembly (6) from fuel ratio control. 6. Remove tube assembly (8) from the fuel filter.7. Disconnect electrical wires (9) from switch.8. Remove line (7) from the fuel transfer pump. 9. Remove cover (10) from the timing gear housing.
Typical Example10. Loosen bolt (11). Leave a gap of 3.2 mm (.125 in.) between washer and the fuel pump drive gear.
Typical Example10. Install tooling (A) to remove fuel pump drive gear (12) from the fuel injection pump camshaft. Remove tooling (A) and bolt (11) and washer. 10. Remove the three nuts (13) that hold the fuel injection pump housing and governor in place. 11. Fasten a nylon strap and hoist and remove the fuel injection pump housing and governor (14). The weight of the fuel injection pump housing and governor is 29 kg (65 lb.).Install Fuel Injection Pump Housing And Governor
Start By:a. remove electric starting motor
Typical Example1. Use the following procedure to put the No. 1 piston top center on the compression stroke. No. 1 piston at top center (TC) on th compression stroke is the starting point for all timing procedures:a. Remove plug from the flywheel housing and remove the breather from the valve cover.b. Install tool (C) in flywheel housing.c. Turn the crankshaft clockwise (as seen from the front of the engine) until a 3/8" - 16 NC × 4 in. long bolt (1) can be installed in the flywheel through the opening for plug.d. If you go past the bolt hole in the flywheel, turn the crankshaft counterclockwise opposite the direction of engine rotation (as seen from the front of the engine) approximately 30 degrees. This procedure will permit the (backlash) gear clearance to be removed from the timing gears when the crankshaft is turned in the direction of engine rotation (clockwise). Do not turn the crankshaft counterclockwise to get bolt hole alignment.
Typical Example The rocker arms for No. 1 piston can be seen with the removal of breather cap (2) from the valve cover.e. Check to see if both rocker arms for the No. 1 piston can be moved by hand (have clearance with the valve stem). The No. 1 piston is at top center on the compression stroke when 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 by hand (have clearance with the valve stem).f. If both rocker arms can not be moved by hand, the No. 1 piston is not at top center on the compression stroke. Remove bolt (1) from the flywheel and turn the crankshaft clockwise (as seen from the front of the engine) one full turn (360°). Install bolt (1) in the flywheel again. Check to see if both rocker arms seen through breather hole can be moved by hand. g. Install tool (A) in the fuel injection pump housing as shown. Push on tool (A) and turn fuel injection pump camshaft (6). When tool (A) engages the groove (slot) in the fuel injection pump camshaft, the fuel injection pump in the No. 1 piston top center position.2. Be sure the O-ring seals (3), (4) and (5) are in position on the fuel injection pump housing and governor. Put clean engine oil on the O-ring seals. 3. Put a nylon strap and hoist on the fuel injection pump housing and governor (7) and install it in position on the timing gear plate and oil manifold. Install the three nuts that hold the fuel injection pump housing to the timing gear plate and the two bolts that hold the governor housing to the oil manifold.
After the fuel injection pump housing and governor are installed on the timing gear plate, be sure the rack is free to move. The O-ring seal (5) on the drive end of the fuel injection pump can hold the rack and prevent free movement of the rack. If the rack does not move freely, the engine can overspeed and be damaged. Serious personal injury can also be the result.
Typical Example4. Install bolt (9) and wahser that hold the fuel pump drive gear (8) to the fuel injection pump camshaft. Install washer (10) with the large outside diameter toward the bolt head. Tighten the bolt finger tight only.
Typical Example5. Install tooling (B).6. Use a 9S7352 Torque Wrench (11) to put a clockwise force of 68 N m (50 lb.ft.) on tooling (B) while bolt that holds the weight is tightened with a 5P7425 Torque Wrench (12) to a torque of 270 25 N m (200 18 lb.ft.).7. Check the timing to make sure it is correct:a. Remove the timing pin (A) from the pump camshaft and the bolt from the flywheel.b. Turn the crankshaft clockwise (as seen from the front of the engine) approximately 1/2 turn. Install the timing pin again.c. While the crankshaft is turned clockwise (as seen from the front of the engine), push on the timing pin (A) until it engages the groove (slot) in the pump camshaft.d. Install the bolt in the flywheel. The timing is correct when the bolt is installed in the flywheel and the timing pin (A) is installed in the groove (slot) in the pump camshaft. 8. Remove tooling (B) and install gasket and cover (13), the timing gear housing. 9. Remove tooling (A), (C) and bolt (1). Install cover (14).10. Connect line (15) to the fuel transfer pump. Connect fuel line (16) to the fuel filter.11. Connect wires (17) to the switch on the fuel filter base. 12. Connect tube assembly (18) to the fuel ratio control. 13. Install turbocharger oil supply and oil return lines (19) on the turbocharger.14. Connect cable (20) to governor lever and install bracket (22) in position on governor.15.