1990 Johnson Evinrude "ES" 9.9 thru 30 Service Manual, P/N 507871, Page 150Get this manual
Installation10, 14 '11 1Apply OMC Gasket Sealing Compound to new exhaust housing to powerhead gasketPlace the gasket over the studs of the powerhead'112Apply Permatex No.2 sealer to the machined diameter of
L!J the lower crankcase head 3Carefully lower the powerhead onto the exhaust housingRotate the powerhead slightly back and forth to align the crankshaft and driveshaft splinesAlign the powerhead studs with holes in the exhaust housing and until the front vertical control shaft engages the pivot hole in the lower engine coverf21 4Apply OMC Gasket Sealing Compound to threads of the five powerhead retaining screwsInstall the screws and the four nuts to torque of 60-84 inIbs(7-9 Nm)5Attach the throttle cable to the powerhead as described in Section 56Secure the fuel hose to the fuel pump7Connect the overboard water indicator hose to the fitting on the lower engine cover8Feed the starter rope through eyelet in the lower engine coverInstall the bumper and the handleTie knot in end of the ropeRelease the temporary knot, allowing the starter rope to rewind normally9Engage the choke knob with the choke knob detent10Install the stop switch ground lead and ignition plate ground lead11Carefully install the stop switch plug and receptacle togetherTo avoid permanent powerhead damage, instruct operator to repeat the original engine break-in procedure as described in Section before putting engine back into normal service