0435264 EVINRUDE PISTON ASSY.

Start By: a. remove fuel injection lines1. Remove the hood and muffler. The weight of the hood is approximately 225 Kg (500 lb.). The weight of the muffler is 79 Kg (175 lb.). 2. Remove timing bolt (1) and bolt (4). Remove cover (2) from the right side of the flywheel housing.3. Remove plug (3). 4. Use tool (A) to turn the engine in a counterclockwise direction (as seen from the flywheel end of the engine) until the No. 1 piston is at top center on compression stroke. Install timing bolt (1) in flywheel. See Finding Top Center Compression Position For No. 1 Piston, Systems Operation Testing And Adjusting. 5. Remove the plug from the front of the injection pump housing. Install tool (B) (as shown) through the hole in the pump housing and into the timing notch in the fuel injection pump camshaft.6. If timing is correct, tool (B) will go into the notch in the fuel injection pump camshaft and the timing bolt will turn freely into the threaded hole in the flywheel. If timing is not correct, remove tool (B) and the timing bolt and do the following procedure.a. Remove the small cover from the automatic timing advance cover.b. Make sure tool (B) is removed from the fuel injection pump camshaft. Loosen four bolts which hold the automatic timing advance unit on the fuel pump camshaft.c. Tighten the bolts with fingers until there is a small amount of friction (slight drag) between the retainer and the timing advance unit. This will prevent movement (backlash) when the gears are turned to the correct timing.d. Use tool (A) to turn the engine in a counterclockwise direction (as seen from the flywheel end) until tool (B) can be installed in the fuel injection pump camshaft.e. Use tool (A) to turn the engine in a clockwise direction (as seen from the flywheel end) a minimum of 30 degrees to remove the movement (backlash) in the timing gears.f. Use tool (A) to turn the engine in a counterclockwise direction (as seen from the flywheel end) until the No. 1 piston is at top center compression stroke. Install the timing bolt in the flywheel.g. Tighten the bolts that hold the automatic timing advance to a torque of 25 N m (20 lb.ft.). Remove tool (B) from the fuel injection pump camshaft.h. Tighten the bolts to a torque of 135 7 N m (100 5 lb.ft.). Remove the timing bolt (1) from the flywheel.7. Turn the engine two complete revolutions and check the timing again. If tool (B) will not go into the notch of the fuel injection pump camshaft, do Steps a through h again. 8. Remove the nut and bolt (7) to disconnect control linkage (6) from the governor.9. Disconnect air line (5) from the air-fuel ratio control. 10. Disconnect fuel lines (8) and (9) from the fuel transfer pump. 11. Remove the bolt that holds fuel line clip (10) in position. Disconnect fuel line (11) from the fuel injection pump housing.12. Disconnect wires (12) from the shutoff solenoid. 13. Remove cover (13) from the automatic timing advance cover. 14. Remove bolts (14) that hold the retainer and automatic timing advance unit to the fuel injection pump camshaft. 15. Remove bracket (16) and bolts (15) from the right side of the fuel injection pump housing. 16. Disconnect drain line (17) from the fuel transfer pump.17. Remove bracket (19) and bolts (18) from the left side of the fuel injection pump housing. 18. Fasten tooling (C) to the fuel injection pump housing with two 3/8" - 16 NC bolts 2 1/4" long. Fasten a hoist to tooling (C). Remove fuel injection pump housing and governor (20). The weight of the fuel injection pump housing and governor is 65 kg (145 lb.). The following steps are for the installation of the fuel injection pump housing and governor.19. Check O-ring seal (21) for wear or damage. If necessary, make a replacement. Put a small amount of 1P808 General Purpose Grease on the O-ring seal.20. Install tool (B) in the notch of the fuel injection pump camshaft.21. Fasten tooling (C) to the fuel injection pump housing with two 3/8" - 16 NC bolts 2 1/4" long. Fasten a hoist to tooling (C). Put fuel injection pump housing and governor in position on the top of the engine.22. Install bolts (18) and bracket (19) to hold the left side of the fuel injection pump housing.23. Connect drain line (17) to the fuel transfer pump.24. Install bolts (15) and bracket (16) to hold the right side of the fuel injection pump housing.25. Install bolts (14) to hold the automatic timing advance unit and retainer to the end of the fuel injection pump camshaft. Tighten bolts finger tight only.26. Install the bolt and nut to hold fuel line clip (10) in position. connect fuel line (11) to the fuel injection pump housing.27. Connect wires (12) to the shutoff solenoid.28. Connect fuel lines (8) and (9) to the fuel transfer pump.29. Connect control linkage (6) to the governor.30. Connect air line (5) to the air-fuel ratio control.31. Check the engine timing. See Remove Fuel Injection Pump Housing And Governor, Steps 2 through 7.32. Install the gasket and cover (13) on the timing advance unit cover after the bolts have been tightened.33. Remove tool (B). Install the plug in the fuel injection pump housing.34. Remove tool (A). Install the cover and plug on the right side of the flywheel housing.35. Install the hood and muffler.End By:a. install fuel injection lines.