0384778 EVINRUDE CAP ASSEMBLY COMMUTATOR

1. Drain the coolant from the cooling system.2. Remove bolts (5) and the retainer from the water pump end.3. Remove four bolts (4) and elbow (3).4. Remove bolts (3) and tube assembly (1). 5. Fasten a hoist to the water pump. Remove bolts (6), bolts (7) and water pump (8). The weight of the water pump is 38 kg (85 lb). The following steps are for the installation of the water pump.6. Make sure the gasket for the water line adapter and the O-ring seal on the pump are in position. Put clean engine oil on the O-ring seal. Fasten a hoist to water pump (8). Install water pump (8) making sure the splines on the water pump shaft are correctly engaged. Install bolts (6) and (7).7. Make sure the O-ring seals on both ends of tube (1) are in position. Put clean engine oil on the seals. Install tube (1), the retainers and bolts.8. Fill the cooling system with coolant to the correct level. See the Maintenance Manual.Disassemble Water Pump
Start By:a. remove water pump 1. Remove elbow (1) from housing assembly (2). Remove the O-ring seal from elbow (1). 2. Remove O-ring seal (5) from the back of housing assembly (2).3. Remove washer (4) that holds shaft assembly (3) in housing assembly (3).
Typical Example4. Remove cover (6) from housing assembly (2). Remove the O-ring seal from cover (6). 5. Loosen nut (8) and the washer that holds impeller (7). Using tooling (A), loosen impeller (7) from the end of the pump shaft. Remove tooling (A), nut (8) and washer and impeller (7) from the pump shaft and housing assembly (2).
Typical Example6. Remove spring (10).7. Using a soft faced hammer, push shaft assembly (3) out of seal assembly (9) and housing assembly (2). Remove seal assembly (9). 8. Remove ceramic seal (11). Remove the rubber ring from housing assembly (2). 9. Remove seal (12) from the back of housing assembly (2).Assemble Water Pump
1. If necessary, replace the two filters in the pump housing at location (13).2. If necessary, replace plug (14) and the seal.3. Using tooling (A), install the seal in the housing assembly. Make sure the lip of the seal is toward the outside. Put clean engine oil on the lip of the seal. 4. Install shaft assembly (3) in housing assembly (2). Install washer (4) and the bolts. Install O-ring seal (5) on the back of housing assembly (2).
Typical Example
Clean water only is permitted for use as a lubricant for assembly. Do not damage or put hands on the wear surface of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal assembly.
5. Install ceramic seal (11) in the rubber ring. Use hand pressure and the tool (which is with the replacement seal) to install the ceramic ring.
Typical Example6. Remove the spring from seal assembly (9). Use hand pressure and the tool, (which is with the replacement seal), to install the seal assembly. Push the seal assembly on the shaft until the seal faces make light contact.
Typical Example7. Install spring (10).8. Install impeller (7). 9. Install the washer and nut (8). Tighten to a torque of 200 25 N m (150 18 lb ft). 10. Make sure the studs for cover (6) are tightened in the pump housing.11. Put clean engine oil on O-ring seal (15) and install it on cover (6). Install cover (6) and the nuts. Tighten the nuts to a torque of 27 4 N m (20 3 lb ft). 12. Put clean engine oil on the O-ring seal and install it in elbow (1). Install elbow (1) on housing assembly (2). Install the bolts.13. Put clean engine oil on the O-ring seal and install it on the back of housing assembly (2).End By:a. install water pumpRemove Auxiliary Water Pump (Fresh Water)
1. Drain the coolant from the cooling system. 2. Remove two clamps (1).3. Remove four bolts (2) and four bolts (3). 4. Remove the bolt that holds wiring harness clip (6) to the oil pan.5. Remove six bolts (5) and bolt (7). 6. Remove bolts (8) and cover (9). 7. Remove bolts (11) and adapter (10). 8. Remove O-ring seal (12).9. If necessary, remove bearing (11) from adapter (10). 10. Using tool (A) and a hoist, pull the pump and drive gear out of the front housing. Remove the pump and drive gear. The weight of the pump and drive gear is 39 kg (86 lb).Install Auxiliary Water Pump (Fresh Water)
1. Install the O-ring seal around the pump body. Put clean engine oil on the seal. 2. Using tool (A) and a hoist, align the pump in the front drive housing. 3. Install the bolt that holds wiring harness clip (6) to the oil pan.4. Install six bolts (5) and bolt (7). 5. Make sure the hole in the bearing is aligned with the oil passage in adapter (10). Using tooling (B) and a press, push bearing (11) into adapter (10) until it is 1.5 0.5 mm (0.06 0.02 in) below the surface of adapter (10). The inside diameter of the bearing must be 75.000 0.055 mm (2.9528 0.0022 in) after assembly. 6. Install O-ring seal (12) in adapter (10). Put clean engine oil on the O-ring seal. Install adapter (12) in the front drive housing. 7. Install the O-ring seal in cover (9) and put clean engine oil on it. Install cover (9) with bolts (8). 8. Position the inlet elbow and install four bolts (3).9. Position the elbow to the auxiliary pump and install four bolts (2).10. Install two clamps (1).11. Fill the cooling system with coolant to the correct level. See the Maintenance Manual.Disassemble Auxiliary Water Pump (Fresh Water)
Start By:a. remove auxiliary water pump (fresh water) 1. Remove O-ring seals (3) and (4).2. Remove the bolts and gear (2) from shaft (1). 3. Remove the bolts and adapter (5) from the housing. Remove the O-ring seal from adapter (5).