GFI_Extract_from_Mod_Conversion_Manual_10-10-12.pdf

Updated Oct-12

MOD 0 CONVERSION

PARYLENE COAT PARTS

3. PARYLENE COAT PARTS

About Parylene Coating:

The Parylene coating process creates a transparent film that adheres to a components surface. In our application, this coating protects vulnerable outboard motor parts from corrosion caused by salt water exposure.

Coating Specifications:

Parylene Type: C Thickness: 0.0017 inches Polymer Requirements: Mil-I-46058 type XY

Vendor:

Para Tech Coating, Inc.

www.parylene.com 35 Argonaut Circle Aliso Viejo, CA 92656

Parts Coated:

o Flywheel o Stator o Oil Pump

NOTE: Parylene is mostly transparent, and it is difficult to distinguish a coated part from an uncoated part.

Parylene coated flywheel

Parylene coated stator

Parylene coated oil pump http://www.parylene.com/

MOD 0 CONVERSION

TPS WATERPROOFING ADAPTOR

6. INSTALL TPS WATERPROOFING

ADAPTOR

Introduction:

The Throttle Position Sensor (TPS) contains a rotating part that is vulnerable to water intrusion.

To fully waterproof this part, a Waterproofing Adaptor (WPA) is necessary. The installation of this adaptor requires modification to the throttle body.

TPS Waterproofing Adaptor (WPA) – Note: this consists of five parts, the plastic outer part, the aluminum rotating part, and three o-rings

Cross section view of TPS WPA showing the position of the three -014 Buna-N 50 O-rings

Throttle Body Modifications:

Two threaded inserts must be installed on the throttle body to allow the TPS and WPA to be attached with two 8-32 screws.

Items Needed:

o ¼” steel punch o Hammer o #3 drill o ¼-28 tap and tap handle o Keensert installation tool (Part No. TKNC 08) o (2) threaded inserts (Keensert Part No.

KNCA0832J)

Threaded Inserts – Keensert Part No. KNCA0832J

Keensert installation tool (Part No. TKNC 08)

Installation Steps:

1. Remove Throttle Body from crank case.

2. Remove TPS

3. Drive out TPS mounting studs using a punch and hammer.

4. Drill mounting stud holes slightly larger using a

#3 drill.

5. Tap holes all the way through using a ¼-28 tap

6. Install threaded inserts using the correct installation and staking tool.

Driving out both TPS mounting studs with a hammer and punch

Mounting studs removed

Drill holes using a #3 drill

Tap holes using a ¼-28 tap

Install both threaded inserts using the installation tool (Keensert Part No. TKNC 08)

Threaded inserts installed and staked

Install the TPS Waterproofing Adaptor Once the throttle body modifications are complete, the TPS Waterproofing Adaptor may be installed along with the TPS and CPS.

Items Needed:

o TPS Waterproofing Adaptor o Plastic outer part o Aluminum rotator o (3) o-rings (-014 Buna-N, Durometer 50) o O-ring lubricant o (2) 8-32 x 7/8 button head cap screw o (2) #8 flat washers o (2) #8 lock washers o CPS o TPS

Items Needed (CPS and lock washers not pictured)

Installation Steps:

1. Install CPS

2. Install throttle lever bushing

3. Attach throttle lever to throttle linkage and install onto throttle body

4. Place TPS Waterproofing Adaptor on top of throttle lever. Make sure the rectangular blade on top of the throttle lever mates with rectangular pocket in the aluminum rotator and the holes in the WPA are aligned with the threaded inserts on the throttle body.

5. Install TPS and fasten with 8-32 screws.

CPS Installed

Throttle lever and throttle lever busing installed

TPS Waterproofing Adaptor placed in position.

TPS in position

TPS fastener, lock washer, and washer configuration

TPS installation complete

INSTALL CYLINDER HEAD DEWATERING VALVES

8. INSTALL CYLINDER HEAD

DEWATERING VALVES

Introduction:

In order to dewater an engine that has been submerged and flooded, water needs to be removed from both the crank case and from above the pistons. The Cylinder Head Dewatering Valves (CHDV) allow water to escape from above the pistons.

Installation Steps:

1. Remove cylinder head

2. Modify cylinder head

3. Reinstall cylinder head onto power head

4. Install CHDV’s

5. Test fit Etec injectors

6. Mark location for clearance cut

7. Modify Etec injectors – add clearance cut

8. Install Etec injectors

Remove Cylinder Head See Evinrude Etec Factory Service Manual

Modify Cylinder Head Two holes will need to be drilled and tapped into the cylinder head. The CHDV’s will be installed in these holes.

Tools Needed:

o #3 center drill o 9/16" end mill o 1/16" drill bit o 23/64" drill bit o M10 X 1.0 Tap o Milling Machine

Tools needed to modify cylinder head

The cylinder head is installed onto the milling bed perpendicularly. To achieve the correct geometry, the mill head should be positioned 22.5 degrees counter clockwise and 15 degrees tilted back.

Milling machine and cylinder head layout for performing milling operations to installing de-watering ports

Using machinist's calipers, scribe an arc onto the cylinder head using the edge of the spark plug recess as the pivot point of the arc. The arc length is 0.535"

Scribing arc #1

Using machinist's calipers, scribe an arc onto the cylinder head using the edge of the fuel injector recess as the pivot point of the arc. The arc length is 0.850"

Scribing arc #2

Where the arcs intersect is the center point of the operation to machine the de-watering valve port.

Location of each hole indicated with two scribed arcs

Align a #3 center drill with the intersection point of the arcs and "Zero" the milling machine.

Perform the center drill operation.

Performing the center drill operation

Using a 9/16" end mill, plunge mill the surface until it is flat. Only a minimal amount of material will be removed to perform this operation.

Flat surface created with 9/16” end mill

Using a 1/16" drill bit, drill through.

Drilling through with a 1/16” drill bit

Drill 0.690" deep using a 23/64" drill bit. (from the flat surface made using the end mill prior)

0.690” deep plunge with 23/64” drill bit

0.690” deep hole completed

Tap to the bottom using a M10 X 1.0 Tap.

Tapping hole with M10 X 1.0 tap

Tapped hole

Chamfer the edge of the tapped hole 1/16" deep.

Chamfering operation

Move the milling machine table 3.5955" in the "Y" direction and repeat the procedure to machine the second dewatering valve port.

Ready to repeat operation on second dewatering port

Reinstall Cylinder Head

See Evinrude Etec Factory Service Manual

Install Cylinder Head Dewatering Valves

Cylinder head with drilled and tapped dewatering valve holes and valves awaiting installation

CHDV - OPEN

CHDV – CLOSED

Install the CHDV’s into the threaded holes created in the cylinder head. Tighten them until the circular crush washers are compressed.

Next, install the Etec injectors. Only loosely tighten the injector bolts, as there will likely be interference between the injectors and the CHDV’s.

Take a marker and mark the point of interference on the injectors.

Install the CHDV’s and Etec injectors. If the CHDV’s are binding against the injectors, mark the spot of interference on the injector with a marker. The arrows mark where the interference may occur.

Once the interference locations are marked on the injectors, remove them.

Next, take a half round hand file and carefully file away the edge of the injector to make a clearance cut. Proceed cautiously, and test fit the injectors until the clearance cut is sufficient to permit operation of the CHDV’s.

A half round hand file is necessary to add a small clearance cut to prevent interference with the dewatering valve

Filling clearance cuts in an Etec injector

Etec injector with completed clearance cuts

Once the clearance cuts are made on both injectors, reinstall the injectors according the to the factory service manual.

CHDV’s and fuel injectors installed