5040160 EVINRUDE Washer 15.2-19-1.9

1. Disconnect hose assemblies (1) and (2). Cap and plug all openings immediately. Remove two bolts (3), washers, nuts and fuel filter bracket (4). 2. Disconnect fuel temperature sensor connector (5). 3. Disconnect atmospheric pressure sensor connector (10) and disconnect turbocharger outlet pressure sensor connector (9).4. Cut tie-wrap (7). Disconnect hose assemblies (2), (6) and (8) and the O-ring seals. Cap and plug all openings immediately.5. Remove nut, washer and clip (11). 6. Remove bolts (12), nut (13) and the washer, remove cover (14) and the gasket. 7. Remove four bolts (16), retainer plate (17) and gear (15). 8. Remove both timing sensors (18). Remove four mounting bolts (20), pin (22) and the seal. Remove two bottom bolts (21) and remove hydraulic pump drive 19). 9. Remove O-ring seals (23) from hydraulic pump drive (19). The following steps are for the installation of the hydraulic pump drive. Check all O-ring seals and the gasket for wear or damage and replace with new parts if necessary. 10. Place O-ring seals (23) in position on hydraulic pump drive (19).11. Lubricate the bore of the front housing and the seal on the hydraulic pump drive lightly with clean engine oil. Put hydraulic pump drive (19) in position in the front housing.12. Install two bottom bolts (21).13. Install four mounting bolts (20). Tighten bolts (20) to a torque of 5 3 N m (4 2 lb ft). Install locating pin (22) and the seal. Tighten locating pin (22) to a torque of 105 10 N m (75 7 lb ft). Tighten mounting bolts (20) again to a torque of 55 7 N m (41 5 lb ft). 14. Put gear (15) in position on the hydraulic pump drive. Install retainer plate (17) with four bolts (16). Tighten the four bolts to a torque of 135 20 N m (100 15 lb ft). With number one piston at top center, align timing marks on gear (15) with the camshaft gear. The timing sensor ends are retractable and must be fully extended before they are installed.15. Connect timing sensors (18). 16. Clean the mating surfaces of the front housing and cover (14). Install a new gasket and cover (14) and secure with bolts (12), nut (13) and the washer. 17. Install clip (11) the washer and the nut. Connect atmospheric pressure sensor connector (10) and connect turbocharger outlet pressure sensor connector (9).18. Connect hose assemblies (8), (6) and (2) and the O-ring seals. Install tie-wrap (7). 19. Connect fuel temperature sensor connector (5). 20. Install fuel filter bracket (4) with two bolts (3), the washers and the nuts. Connect hose assemblies (2) and (1).End By:a. install hydraulic pumpDisassemble & Assemble Hydraulic Pump Drive
Start By:a. remove hydraulic pump driveFluid Spillage Containment
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "Tools And Shop Products Guide", NENG2500 for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose of fluids according to local regulations and mandates. 1. Remove three screws (1) and retainer plate (2). Remove two bolts (3) from hydraulic pump drive (4). 2. Remove four bolts (5) and separate housing assembly (6) from housing assembly (7). 3. Remove gasket (8) from housing assembly (6). 4. Remove two bolts (9) and the washers. Remove thrust plate (10). 5. Remove shaft assembly (12) and engine pump drive gear (11) from housing assembly (6). 6. Press shaft assembly (12) out of oil pump drive gear (11). 7. Disconnect fuel temperature sensor (14). If necessary remove bearings (16), dowel (15) and fittings (13) from housing assembly (6). 8. Remove gear and shaft (18) from housing assembly (7). 9. Disconnect atmospheric pressure sensor (19). If necessary remove bearings (20) from housing assembly (7). The following steps are for the installation of the hydraulic pump drive. Check all O-ring seals and the gasket used in the removal procedure. If they are worn or damaged replace them with new parts. 10. Connect atmospheric pressure sensor (19) and install bearings (20) in housing assembly (7). 11. Install gear and shaft (18) in housing assembly (7). Lubricate the shaft and bearing bores with clean engine oil before installation. Install bearings (16) with the bearing clinch butt joint oriented toward the top of housing assembly (6).12. Install fittings (13), dowel (15) and bearings (16). Connect fuel temperature sensor (14) in housing assembly (6).13. Press oil pump drive gear (11) onto shaft (12) until it makes contact on the counterbore. 14. Install oil pump drive gear (11) and shaft (12) into housing assembly (6). Lubricate the shaft and bearing bores with engine oil before installation. 15. Put thrust plate (10) into position and install bolts (9) and the washers. Lubricate the thrust plate lightly with clean engine oil. 16. Install gasket (8) on housing assembly (6). Clean both housing assembly surfaces where the gasket will be used. 17. Put housing assembly (7) in position on housing assembly (6). Install four bolts (5) and four bolts (3)18. Place retainer plate (2) in position and install three screws (1) in hydraulic pump drive (4).End By:a. install hydraulic pump drive