1996 Johnson Evinrude "ED" 9.9 thru 30 2-Cylinder Service Manual, P/N 507122, Page 155Get this manual
Installation INotel 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 sealer
IT] 2Install both grommets and water tubes in inner exhaust tube 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)
3Apply liberal amount of Permatex No.2 sealer to the machined diameter of the lower crankcase head
4Carefully lower the powerhead into the exhaust housing as follows:
W Install the long water tube against the exhaust tube
Guide the long water tube into the water tube opening in the exha ust housingGuide the small water tube into the opening in the rear of the exhaust housing
OMC Gasket Sealing Compound to the six powerhead retaining screws and install the screwsTighten the six powerhead retaining screws to torque of 60-84 inIbs(7-9 Nm)