0215881 EVINRUDE STRIPE - Starboard - Blue

Before any service work is done on the fuel system, the outer surface of the injection pump housing must be clean.
The fuel injection pump housing and governor has been removed from the engine for illustration purposes. 1. Remove flange (1) and the flange assembly from the cover.2. Remove cover (2) from the pump housing. 3. Remove the bypass valve (3) and springs from the pump housing. 4. Install tooling (A) on the fuel injection pump and loosen the bushing from the pump housing. Do not loosen screws (4) that hold the levers to the shaft when the pumps are removed or installed. If the levers are moved, fuel pump calibration will be changed. 5. Remove the fuel injection pump (5) from the pump housing. The sleeve on the plunger will slide off the lever as the pump is removed.6. Do Steps 4 and 5 for the remainder of the pumps.Install Fuel Injection Pumps
1. Turn the camshaft until the lifter for the pump to be installed is at its lowest position. 2. Install the fuel injection pump (1) in the bore of the pump housing.3. The sleeve (2) will be engaged with the lever when the pump is installed correctly.
If the levers have been moved on the shaft, fuel pump calibration must be made. (See TESTING AND ADJUSTING).
4. Tighten the bushing with tooling (A) to a torque of 60 5 lb. ft. (80 7 N m).5. Do Steps 1 through 4 for the remainder of the pumps. 6. Install the bypass valve and spring (3) in the pump housing. 7. Install the cover (5) on the pump housing. Be sure the spring (3) is in the bore in the cover.8. Install the flange (4) and the flange assembly on the cover.Disassemble Fuel Injection Pumps
1. Remove bushing (1) and O-ring seal (7) from bonnet (2).2. Remove ring (3) from the bonnet and barrel (4).3. Remove check valve assembly (9) and spring (8) from the bonnet.4. Remove spring (10) and retainer washer (5).
Keep the plunger and sleeve with their respective barrel for installation. Do not use plungers, sleeves and barrels with other plungers, sleeves and barrels.
5. Remove plunger (11) and sleeve (6).Assemble Fuel Injection Pumps
1. Install the sleeve (4), plunger (5), spring (2) and washer (3) on barrel (1).
Be sure the sleeve and plunger are installed in their original barrel and the large hole in the plunger is up. The sleeve must be installed with the thin flange up.
2. Install the check valve assembly and spring in the bonnet. Connect the barrel and bonnet with the ring. Install the seal and bushing on the bonnet.end by:a) install fuel injection pumpsRemove Fuel Transfer Pump
start by:a) remove fuel injection pump housing and governor 1. Install the fuel injection pump housing on tool (A).2. Remove seven bolts (1) and governor housing (2). Later fuel injection pump housings have a thrust washer for the fuel injection pump camshaft. The thrust washer is behind the flange for the flyweights on the camshaft. To hold the thrust washer in place governor shaft (3) and the camshaft must be held in toward the fuel transfer pump any time sleeve (4) is removed. 3. Remove the plug from the cover and install tool (B) in the hole as shown. Turn the injection pump camshaft until tool (B) can be pushed into the groove (slot) in the camshaft. Any time the drive sleeve is removed from the camshaft a new one must be installed. The camshaft has serrations (splines) that cut grooves into the drive sleeve when it is installed to give a positive drive connection. If a formerly used drive sleeve is installed again it can slip (slide around) on the camshaft.4. Install tool (C) in the threads of sleeve (4). Tighten the bolt until the sleeve can be removed. 5. Remove four bolts (5) and fuel transfer pump body (6) from the housing. 6. Disconnect drain line (7) from the fitting on the back of fuel transfer pump body. 7. Remove gear (8) and O-ring seal (9) from the pump body. 8. Remove seals (10) from the pump body. 9. Remove drive gear (11) and the key from the camshaft.Install Fuel Transfer Pump
The fuel injection camshaft must be held in toward the fuel transfer pump during installation of the fuel transfer pump parts to hold the camshaft thrust washer in its counterbore. The thrust washer will be damaged when the sleeve is installed on the camshaft if it is not in the correct position. 1. Install key (1) and drive gear (2) on the shaft. 2. Put No. 3 Aviation Permatex on the outside diameter of the seals for body (3).3. Use tooling (B) to install the first seal in the body with the lip down and the second seal with the lip up. Install the first seal to a depth of .453 in. (11.5 mm) and the second seal to a depth of .030 in. (0.75 mm).4. Remove the extra permatex from the body and seals after installation. Be sure the drain hole between the seals is open. 5. Install O-ring seal (4) and gear (5) on the body. 6. Install tool (C) in the end of the fuel injection pump camshaft. Connect drain line (6) to the fitting on the back of the body and put the body in position on the fuel injection pump housing. Install the bolts that hold the body in place.7. Install tool (E) in the camshaft so it will not turn. 8. Put a new sleeve (7) on the camshaft. A new drive sleeve must be installed because a used drive sleeve can slip (slide around) on the camshaft. 9. Tighten the sleeve into position on the shaft with the 4B4280 Washer of tooling (D) approximately .25 in. (6.4 mm). Tighten the sleeve the remainder of the way with the 9N5022 Washer until the sleeve is at bottom. This is the washer which is on the tachometer drive shaft.
Do not hit the sleeve to install. Damage to the governor