1992 Johnson Evinrude "EN" 90 deg. Cross V Service Manual, P/N 508145, Page 261Get this manual
Installation
rv seal innerOMC Adhesive sealantnewlower exhaust housing 1Apply to housing surfacesPosition two seals on
Apply OMC Triple-Guard grease to seal outer surfaces and posi tion housing on jet drive housing 2Slide jet housing into place, making sure driveshaft engages crankshaft, water tube enters water pump, and lower inner exhaust housing does not slip out of position f31 3Apply OMC Gasket Sealing Compound to threads of jet housing retaining screws and rear exhaust housing screwInstall two 38-16 212 inscrews in forward holes and two 38 -16 inscrews in rear holes Install rear spacer and screwTorque all screws to 18-20 ftIbs(24-27 Nm)4Install key, bushing, shims, tab-washer, and nut on driveshaftBe sure shims are placed in original positionRefer to Impeller Clearance Adjustmentf'4l 5When proper clearance adjustment is achieved, torque impeller nut to 16-18 ftIbs(22-24 Nm)1sl 6Using new tab-lock washer, bend tabs around driveshaft nut to secure the assemblyf61 7Assemble intake housing to jet housing Apply OMC Gasket Sealing Compound to threads of six retaining screws, and install them finger tight onlyCheck for any rubbing or binding If clearance is greater on one between casing liner and side, verify that intake housing is centeredTorque screws in crisscross pattern to 10-12 ftIbs(14-16 Nm)8Recheck impeller clearance after shimming adjustment has been performedf'7l 9Remove vent hose to expose grease fittingUsing OMC Marine Wheel Bearing Grease and grease gun, add enough grease to fill the vent hoseReplace hose on fitting