WATER SEPARATING FUEL FILTER KIT, P/N 5007045 INSTALLATION INSTRUCTIONS
Use this instruction sheet when installing Water Separating Fuel Filter Kits on Evinrude® E-TEC® 60°V outboards (V4 / V6). Includes water-in-fuel sensor. DO NOT install on any other models.
For safety reasons, this kit should be installed by an authorized Evinrude®/Johnson® dealer. This instruction sheet is not a substitute for work experience. Additional helpful information may be found in other service literature for your engine.
This instruction sheet uses the following signal words identifying important safety messages.
Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, CAN result in severe injury or death.
Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate personal injury or property damage. It also may be used to alert against unsafe practices.
IMPORTANT: Identifies information that will help prevent damage to machinery and appears next to information that controls correct assembly and operation of the product.
These safety alert signal words mean:
YOUR SAFETY IS INVOLVED!
Always follow common shop safety practices. If you have not had training related to common shop safety practices, you should do so to protect yourself, as well as the people around you.
It is understood that this instruction sheet may be translated into other languages. In the event of any discrepancy, the English version shall prevail.
DO NOT do any repairs until you have read the instructions and checked the pictures relating to the repairs.
Be careful, and never rush or guess a service procedure. Human error is caused by many factors: carelessness, fatigue, overload, preoccupation, unfamiliarity with the product, and drugs and alcohol use, to name a few. Damage to a boat and outboard can be fixed in a short period of time, but injury or death has a lasting effect.
When replacement parts are required, use Evinrude/Johnson Genuine Parts or parts with equivalent characteristics, including type, strength and material. Using substandard parts could result in injury or product malfunction.
Torque wrench tightening specifications must be strictly followed. Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Definite resistance to turning must be felt when reusing a locking fastener. If replacement is specified or required because the locking fastener has become weak, use only authorized Evinrude/Johnson Genuine Parts.
If you use procedures or service tools that are not recommended in this
instruction sheet, YOU ALONE must decide if your actions might injure people or
damage the outboard.
WATER SEPARATING FUEL FILTER KIT (Evinrude E-TEC 60°V)
|Ref||P/N||Name of Part||Qty|
|5007045||WATER, SEPARATING FUEL FILTER KIT|
|1||317893||*TIE STRAP, 4 in.||1|
|2||320107||*TIE STRAP, 7 in.||1|
|5||907833||*TIE STRAP, 11 in.||1|
|6||*HOSE, length 5 in. (127 mm) A||1|
|7||348839||*CLAMP, ear - 17.0 mm||3|
A Cut hose from bulk roll
- P/N 772571
Protect against hazardous fuel spray. Before starting any fuel system service, carefully relieve fuel system pressure. Refer to Service Manual.
To prevent accidental starting while servicing, disconnect the battery cables at the battery.
Prior to installation of water separating fuel filter assembly, the existing in-line fuel filter and a fuel supply hose must be removed.
Remove top hose clamp and hose from fuel filter.
Remove screw and filter clamp. Remove tie strap on V4 models.
Remove hose clamp and hose from fuel pump outlet fitting.
Remove lower recirculation hose.
Replace lower recirculation hose with longer hose provided. Fasten to cylinder block fitting with 4 in. tie strap provided.
Remove hose/wire clamp and reinstall in orientation shown.
IMPORTANT: Do not allow hoses to be pinched between bracket and cylinder block.
Position filter bracket assembly on cylinder block as shown. Fasten bracket to cylinder block using washers on screws. Torque screws to 60 to 84 in. lbs. (7 to 9 Nm).
Cut 2 in. (50 mm) from existing fuel outlet hose (V4 only).
Install fuel outlet hose to center fuel fitting on fuel filter bracket. Fasten hose connection using 17 mm ear clamp.
Install new fuel supply hose as shown. Connect to fuel outlet fitting of fuel pump and outer fuel fitting on fuel filter bracket. Fasten hose connections using 17 mm ear clamps.
Remove water-in-fuel sensor wiring connector from holder on flywheel cover.
Cut tie strap to route sensor wire (V6 only).
Route water-in-fuel sensor wiring from fuel bracket to connect with water-in-fuel sensor wiring at flywheel cover.
Make connections and position connectors as shown. Install tie straps as shown.
IMPORTANT: Position fuel hoses as shown. Do not allow fuel hoses to rub. Do not allow stator connectors to rub on fuel hoses.
Make sure no fuel or oil hoses are pinched or restricted.
Prime and pressurize fuel system and check for fuel leaks. Repair all fuel leaks.
Start outboard and check operation. Observe fuel hoses and connections.
Repair all fuel leaks.