5007531 EVINRUDE Service Manual - English

1. Thoroughly clean the area around each fuel line connection. Disconnect fuel injection line (1) from the adapter. Disconnect fuel injection nozzle (2) from the adapter. If more clearance is needed to remove the nozzle always remove the fuel line. Do Not bend it out of the way.2. Remove clamp (3) and the spacer that holds the fuel injection nozzle in place.
Never use force to remove the fuel injection nozzles. If necessary, use a twisting motion to pull the fuel injection nozzle out of the cylinder head.
3. Remove the adapter (4) from the cylinder head. Remove the fuel injection nozzle.Install Fuel Injection Nozzles
Always check the fuel injection nozzles for leakage, opening pressure and the shape and amount of fuel (spray pattern) coming out of the nozzles with tool (A) before installing the nozzles in the cylinder head. See TESTING FUEL INJECTION NOZZLES in TESTING AND ADJUSTING.
1. Remove carbon seal dam (2) with pliers. Remove compression seal (1). 2. Install a new compression seal on the nozzle. Install a new carbon seal dam with tool (B).3. Make sure the bore in the cylinder head and the fuel inlet fittings are clean. 4. Install new O-ring seals on adapter (3) and fuel injection nozzle (4).5. Install the fuel injection nozzle in the head. Use a twisting motion to push the nozzle into its correct position. Never put lubricant on the nozzle or bore in the cylinder head.6. Install the adapter in the head. Connect the nozzle and fuel injection line to the adapter. Tighten the nuts to a torque of 30 5 lb. ft. (40.7 6.8 N m).7. Install the spacer and clamp that hold the nozzle to the cylinder head. end by: a) install rocker shaftsDisassemble Fuel Injection Nozzles
start by: a) remove fuel injection nozzles Do not disassemble any nozzle until testing has shown that disassembly is needed. Check each nozzle with tool (A) for leakage, opening pressure, and the shape and amount of fuel (spray pattern) coming out of the nozzle. Do not clean or make an adjustment to any nozzle that has a large (excessive) amount of return leakage. Excessive return leakage can be an indication of nozzle failures that can not be corrected with an adjustment or cleaning and can cause engine damage. See TESTING 9L6969 FUEL INJECTION NOZZLES in TESTING AND ADJUSTING.
Keep the work area and all tools extra clean. Be careful not to cause damage to the parts during disassembly and assembly of the nozzles.
1. Remove cap (1) from the fuel injection nozzle. 2. Put the nozzle in tool (B). Put tool (B) and the nozzle in a vise. Do not put any part of a nozzle directly in a vise. Loosen locknut (2) while holding the lift adjustment screw. Turn the lift adjustment screw (3) counterclockwise one turn. Hold the lift adjustment screw (3) with a 5/64" hex wrench and remove the locknut (2).
If the lift adjustment screw is not turned counterclockwise one turn, the valve can be bent or the seat for the valve can be damaged when the pressure adjustment screw is turned.
3. Loosen the locknut (4) that holds the pressure adjustment screw. Use tool (D) to hold the pressure adjustment screw. 4. While holding the nozzle in one hand, tilt the nozzle and remove the pressure adjusting screw and locknut, spring, seat and valve. 5. If the valve does not slide out of the nozzle, install tool (C) and remove valve as follows: a) Push valve into nozzle with tool (C) until valve is against bottom of nozzle.b) Push down on body of tool (C) to engage collet on valve with tool (C).c) Turn nut counterclockwise and remove valve from the nozzle body. Put the parts in solvent to loosen carbon and deposits of foreign material. The body is assembled with an epoxy material and must not be in contact with the solvent for more than one to two hours. See SPECIAL INSTRUCTION FORM NO. FMO55225 for the correct method of cleaning the nozzle.Assemble Fuel Injection Nozzles (9L6969 Nozzles)
Make sure all of the parts have been thoroughly cleaned before assembling the nozzles. Flush the body to remove any debris or lapping compound.1. Put clean fuel on all of the parts. 2. Put valve (1) in position in the body as shown.3. Install lift adjusting screw (6) into pressure screw (5). Turn the lift adjusting screw two or three turns. Install the locknut (4) on the pressure adjusting screw (5).4. Put spring (3), and seat (2) in position on the adjusting screw (5).5. Put seat (2) in contact with the valve and push the valve into position in the body. Tighten the pressure screw by hand.6. Make an adjustment to the opening pressure of the nozzle as controlled by the pressure adjusting screw with tool (B). See TESTING 9L6969 FUEL INJECTION NOZZLES, OPENING PRESSURE TEST in TESTING AND ADJUSTING.7. Make an adjustment to the valve lift as controlled by the lift adjusting screw with tool (B). See TESTING 9L6969 FUEL INJECTION NOZZLES, VALVE LIFT ADJUSTMENT in TESTING AND ADJUSTING. 8. Put the nozzle in position in tool (A). Put tool (A) and the nozzle in a vise. Hold the lift adjustment screw (7) with a 5/64" hex wrench and tighten the locknut (8) until the adjusting screw will not turn. 9. Tighten the locknut for the pressure adjustment screw to a torque of 70 to 80 lb. in. (7.91 to 9.04 N m).10. Tighten the locknut for the pressure adjustment screw to a torque of 35 to 45 lb. in. (3.95 to 5.08 N m). 11. Install the cap on the fuel injection nozzle. Use tool (C) to tighten the cap to a torque of 110 to 120 lb. in. (12.43 to 13.56 N m). end by: a) install fuel injection nozzle