1992 Johnson Evinrude "EN" 9.9 thru 30 Service Manual, P/N 508142, Page 166Get this manual
Installation Remove the gearcase as described in Section 6This will aid in guiding the water tube into the water pump grommet 1Install new powerhead to exhaust housing gasketInstall dry, use no sealertube Center water tube in grommetsDo not allow water tubes to touch inner exhaust tubePosition inner exhaust tube on powerheadTighten the screws to torque of 60-84 in Ibs(7-9 Nm)f21 3Apply liberal amount of Permatex No.2 sealer to the machined diameter of the lower crankcase head CD4Carefully lower the powerhead into the exhaust housing as follows: Install rubber band to hold the long water tube against the exhaust tube Guide the long water tube into the water tube opening in the exhaust housing813078
f1l 2Install both grommets and water tubes in inner exhaust
Guide the small water tube into the opening rear of the exhaust housing
Before the powerhead is completely down, place small washer over large washer on the three lower pan su pport studs Guide the vertical control shaft into the vertical control shaft gear Place the remaining small and large washers onto the lower pan support studsStart the three nuts but do not tighten at this timeBe sure to place the ground lead on the rear stud Finish lowering the powerhead Tighten the three nuts securely Apply OMC Gasket Sealing Compound to the six powerhead retaining screws and install the screwsPlace the two longer screws in aft holesBe sure to place the ground lead on the front screw as shownTighten the six powerhead retaining screws to torque of 60-84 in Ibs(7-9 Nm)