5040209 EVINRUDE CLIP 6.8

1. Remove two bolts (1). Remove two bolts (2).2. Remove three bolts (5). Remove cover (6) and tube assemblies (3) and (4). 3. Remove nuts (8) and four bolts (7). Remove the water pump.Install Water Pump
1. Put the water pump in position on the timing gear cover. Install nuts (8) and one bolt that hold the pump to the timing gear cover.2. Install four bolts (7).
Typical Example3. Put clean engine oil or glycerin on O-ring seals (9). Install elbow (3). 4. Put cover (6) in position on the water pump. Install bolts (5) that hold the cover to the water pump and bolts (1) and (2) that hold tube assemblies (3) and (4).End By:a. install expansion tankb. fill cooling system to proper levelDisassemble Water Pump
Start By:a. remove water pump 1. Remove O-ring seal (1) from adapter (2).2. Remove adapter (2) with a screwdriver. Remove the seal from the edge of adapter (2).3. Remove bolt (3) and washer. 4. Remove impeller (4) from the water pump housing with Tool (A). 5. Remove seal assembly (5). Remove ring and seal (6). 6. Remove the bolt and washer that hold gear (7) on the water pump shaft.7. Remove gear (7) with Tool (B).8. Remove bolts and retainer (9).9. Remove O-ring seal (8). 10. Remove shaft (10) and bearings as a unit.11. Remove bearing (11), spacer (12) and bearing (13) from shaft (10).12. Remove lip-type seal from the gear side of the water pump. Remove ring and seal from the impeller side of the water pump.Assemble Water Pump
1. Put clean engine oil or glycerin on the lip of seal (1). Install seal (1) as shown with Tool (A). 2. Install bearing (4), spacer (3) and bearing (5) on shaft (2). Install shaft (2) in the pump housing. 3. Install retainer (7) and O-ring seal (8).4. Install gear (6). Install washer and bolt that hold gear (6) to shaft (2).
Clean water only is permitted for use as a lubricant for assistance at installation. 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. Put ceramic ring (10) in position in the rubber seal (9). Use hand pressure and the tool (which is with the replacement ring) to install the ceramic ring in the housing. 6. Remove the spring from seal assembly (11). Use the tool that is with the replacement ring to install seal assembly (11). Push the seal assembly on the shaft until the carbon ring (on the seal assembly) makes light contact with the ceramic ring. 7. Install spring (12) on the seal assembly and impeller (13) on the shaft. Install the bolt and washer on the shaft. Tighten the bolt to a torque of 39 3 N m (29 2 lb ft). 8. Install O-ring seals (14) on adapter (15). Put clean engine oil on O-ring seals.9. Install adapter (15) in the pump housing. Make sure the notch in the adapter is in alignment with dowel (16).End By:a. install water pump