5040542 EVINRUDE PROPELLER SHAFT HOUSING ASSEMBLY

start by:a) remove rocker shafts and push rodsb) remove front drive housing 1. Remove the bolts that hold the brackets for shaft (2) to the front of the cylinder block. Disconnect the levers on shaft (2) from the levers on shafts (1) and remove shaft (2) from the engine. 2. Remove levers (4) and (5) and brackets (3) from shaft (2). 3. Remove bearings (6) from brackets (3) with tool group (A). 4. Remove access covers (7) from over the camshafts. 5. Remove bolts (9) and the caps that hold the levers of rod assemblies (8) to the fuel control rod.6. If necessary, remove the cover from the front right side of the flywheel housing and use tool (B) to turn the engine flywheel until the camshaft is moved in a position so the levers of rod assemblies (8) can be removed between the cylinder block and camshaft. 7. Remove bolts (11) and remove lever assemblies (10) and fuel control rod assemblies (8) as a unit from the cylinder heads. See Step 6 if the levers on the lower ends of rod assemblies (8) do not have enough clearance to be removed from the engine. 8. Remove locknut (12) and the washer to remove rod assembly (8) from lever assembly (10). 9. Remove levers (14) from control shafts (1).10. Remove the bolts and supports (13) from each side of the engine. 11. If necessary, remove bearings (15) from supports (13) with tool group (A). 12. Pull control shaft (1) out of each side of the engine block. 13. Remove the bolts and remove two bracket assemblies (16) on each side of the 3512 Engine. The 3508 Engine has only one bracket assembly (16) on each side. 14. If necessary, use tool group (A) to remove bearings (17) from bracket assemblies (16).Install Fuel Injection Control Linkage
1. Use tool group (A) to install the bearings in bracket assemblies (1) until they are in the center of their bores. Check the bore in the bearings after assembly. The bearing bores must be 21.925 0.015 mm (.8632 .0006 in.). 2. Install two bracket assemblies (1) on each side of the 3512 Engines. Install one bracket assembly (1) on the 3508 Engines. 3. Install control shaft (2) on each side of the engine block. 4. Use tool group (A) and install the bearings in the center of the bores in supports (3). Check the bore in the bearings after assembly. The bearing bores must be 21.925 0.015 mm (.8632 .0006 in.). 5. Install supports (3) to hold the front of the control shafts. Install levers (4) on each of the control shafts. 6. Connect lever assembly (6) to rod assembly (5). 7. Install lever assembly (6) and rod assembly (5) as a unit in each cylinder head. If necessary, use tool (B) to turn the engine flywheel until the camshaft moves enough to permit the lever of the rod assembly to move into position.8. Make sure lever assembly (6) is engaged correctly with the fuel injection pump rack and install the two bolts to hold it in place. 9. Make sure the lever for the fuel control and assembly is in position on the control shaft and install the bolt and cap (7). 10. Install access covers (8) and seal over the camshafts and control rods. 11. Use tool group (A) and install the bearings in the center of the bores in front control shaft brackets (9). Check the bore in the bearings after assembly. The bearing bores must be 21.925 0.015 mm (.8632 .0006 in.). If necessary, make a replacement of the pins in brackets (12). The pins must extend 8.0 0.5 mm (.315 .020 in.) above the surface of brackets (9). 12. Install brackets (9) and levers (10) on the ends of front control shaft (11). 13. Put shaft (11) in position on the front of the engine. Make sure levers (10) and (4) are engaged correctly and install the bolts to hold the brackets and shaft (11) to the engine. After assembly the control shafts must turn freely by hand and the linkage must return to the "SHUTOFF" position when it is turned and released. See TESTING AND ADJUSTING section for the correct adjustment of the fuel injection control group.end by:a) rocker shafts and push rodsb) front drive housing