5040177 EVINRUDE Pump Case (Lower)

Start By:a. remove timing gear cover
Do not turn the crankshaft with the camshaft gear removed. Damage can be caused to the pistons and valves, or both.
1. Remove three bolts (2) and thrust plate (1). 2. Remove three bolts (4), plate (5) and idler gear (3). 3. Check the condition of bearing (6) in idler gear (3). If bearing (6) is worn or damaged, use a new part for replacement. Use Tool (A) to remove and install bearing (6) in idler gear (3). 4. Remove bolts (8), plate (9) and gear (7). 5. Check the condition of bearing (10) in gear (7). If bearing (10) is worn or damaged, use a new part for replacement. Use Tool (A) to remove and install bearing (10) in gear (7). 6. Remove bolts (12), plate (13) and gear assembly (11).7. Check the condition of bearing (14) in gear assembly (11). If bearing (14) is worn or damaged, use a new part for replacement. Use Tool (A) to remove and install bearing (14) in gear assembly (11).
If the nuts for shaft assembly (15) are loosened, or if shaft assembly (15) is removed or moved in any way, the backlash for the cam gear and idler gear (3) will have to be adjusted at reassembly. Refer to Systems Operation, Testing & Adjusting Module, for further information.
8. Check the condition of shaft assembly (15). If the bearing diameter of the shaft is worn or damaged, remove the nuts and replace shaft assembly (15) with a new part. For assembly purposes, the torque for the nuts and bolts holding shaft assembly (15) is 47 9 N m (35 7 lb ft).9. Check the condition of shaft assembly (16). If the bearing diameter of the shaft is worn or damaged, remove the nuts and replace shaft assembly (16) with a new part. For assembly purposes, the torque for the nuts and bolts holding shaft assembly (16) is 47 9 N m (35 7 lb ft). 10. Check the condition of the shaft (17). If the bearing diameter of the shaft is worn or damaged use new parts to replace shaft (17) and bolts (18). Do not reuse bolts (18). Tighten bolts (18) to torque of 50 10 (37 7 lb ft). 11. Remove bolts (20) and plate (21).12. Remove seal assembly (19) from plate (21). 13. Replace O-ring seals (22) and (23) with new parts on seal assembly (19). The following steps are for the installation of the timing gears and plate.14. Install a new gasket on the back of plate (21).15. Install plate (21) and bolts (20). Evenly tighten bolts (20).16. Position O-ring seals (22) and (23) and seal assembly (19) in plate (21). Install bolts (2) into seal assembly (19). Evenly tighten bolts (2) until seal assembly (19) and O-ring seal (22) is seated against the cylinder head. Remove bolts (2). 17. Put gear assembly (11) on shaft (17) make sure the "V" timing marks are aligned on gear assembly (11) and the crankshaft gear as shown. Install plate (13). Install and tighten bolts (12) to a torque of 28 7 N m (21 5 lb ft).18. Put gear (7) on shaft assembly (16). Install plate (9). Install and tighten bolts (8) to a torque of 28 7 N m (21 5 lb ft).19. Put idler gear (3) on shaft assembly (15). Install plate (5). Install and tighten bolts (4) to a torque of 28 7 N m (21 5 lb ft).20. Install thrust plate (1) and three bolts (2).End By:a. install timing gear cover