0209799 EVINRUDE PLATE, Applique, front

Table 1
Required Tools
Tool Part Number Part Description Qty
A 388-1289 Capping Kit 1 Start By:
If the Diesel Particulate Filter (DPF) assembly is mounted above the valve mechanism cover, removal of the DPF assembly and mounting bracket will be necessary. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Remove" and Disassembly and Assembly, "Support and Mounting (CEM) - Remove and Install" for the correct procedures.
Remove the fuel manifold. Refer to Disassembly and Assembly, "Fuel Manifold (Rail) - Remove and Install" for the correct procedure.
Remove the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove" for the correct procedure.
Remove the secondary fuel filter base. Refer to Disassembly and Assembly, "Fuel filter Base - Remove and Install (Secondary Fuel Filter)" for the correct procedure.
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct training.Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information.Refer to Systems Operation, Testing and Adjusting Manual, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Plug or cap all open ports and tube assemblies.
Illustration 1 g02671257
If necessary, remove the exhaust gas recirculation valve (EGR Valve). Refer to Disassembly and Assembly, "Exhaust Gas Recirculation Valve - Remove and Install" for the correct procedure.
Remove bolts (2) and bolt (3) from valve mechanism cover (1).
Remove valve mechanism cover (1) from the cylinder head.
Illustration 2 g02671282
Typical example
Remove gasket (4). Installation Procedure
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 3 g02671282
Typical example
Illustration 4 g02908978
Thoroughly clean all gasket surfaces of valve mechanism cover (1). Note: Ensure that the recess for the gasket is free from oil.
Clean the gasket surfaces of the cylinder head.
Install a new gasket (4) to valve mechanism cover (1). Note: Ensure that the gasket is fully seated into the groove of the valve mechanism cover.
Position valve mechanism cover (1) onto the cylinder head.
Install bolts (2) and bolt (3) to the valve mechanism cover.
Temporarily install the bolts used to secure the fuel manifold in Positions (X) finger tight.
Illustration 5 g02671296
Tighten the bolts in the numerical sequence that is shown in Illustration 5. Tighten the bolts 1 through 7 to a torque of 10 N m (89 lb in)Tighten the bolt 8 to a torque of 27 N m (239 lb in)Repeat Step 7 in order to ensure the correct torque.
Remove the bolts used to secure the fuel manifold in Positions (X).
If necessary, install the exhaust gas recirculation valve (EGR Valve). Refer to Disassembly and Assembly, "Exhaust Gas Recirculation Valve - Remove and Install" for the correct procedure. End By:
Install the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove" for the correct procedure.
Install the secondary fuel filter base. Refer to Disassembly and Assembly, "Fuel filter Base - Remove and Install (Secondary Fuel Filter)" for the correct procedure.
Install the fuel manifold. Refer to Disassembly and Assembly, "Fuel Manifold (Rail) - Remove and Install" for the correct procedure.
If the Diesel Particulate Filter (DPF) assembly is mounted above the valve mechanism cover, install the DPF assembly and mounting bracket. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Remove" and Disassembly and Assembly, "Support and Mounting (CEM) - Remove and Install" for the correct procedures.