0776824 EVINRUDE CABLE ASSEMBLY, 18 ft. (5.5m)

INSTALL WATER PUMP
1. 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 (1) and put water pump (1) in position on the engine. Make sure the splines of the pump shaft are correctly engaged and install the bolts to hold the pump to the oil and water pump drive adapter.2. Install bolts (2) to hold the pump to the water line adapter.3. Install damper guard (3) on the engine.4. Make sure the O-ring seals on both ends of the tube (4) are in position and put clean engine oil on the seals. Put tube (4) in position and install retainers and bolts to hold the tube in position.5. Connect the water supply line to the water pump inlet.6. Fill the cooling system with coolant to the correct level. DISASSEMBLE WATER PUMP
start by:a) remove water pump1. 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 (2).4. Remove cover (6) from housing assembly (2). Remove the O-ring seal from cover (6).5. Loosen bolt (8) and the washer that hold impeller (7) to the pump shaft. Use tooling (A) to loosen impeller (7) from the end of the pump shaft. Remove tooling (A), bolt (8), the washer and impeller (7) from the pump shaft and housing assembly (2).6. Remove spring (10) from seal assembly (9) and shaft assembly (3).7. Use a soft faced hammer and push shaft assembly (3) out of seal assembly (9) and housing assembly (2). Remove seal assembly (9) from housing assembly (2). 8. Remove ceramic seal (11) from the rubber ring. 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, make a replacement of the two filters in the pump housing at location (1).2. If necessary, make a replacement of plug (2) and the seal.3. Use tool group (A) to install the seal in the housing assembly. Make sure the lip of the seal is toward the outside as shown. Put clean engine oil on the lip of the seal.4. Install shaft assembly (3) in housing assembly (4). Install washer (5) and the bolts to hold shaft assembly (3) in position.
CAUTION 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. Put ceramic seal (6) in position in the rubber ring. Use hand pressure and the tool (which is with the replacement seal) to install the ceramic seal. 6. Remove spring from seal assembly (7). Use hand pressure and the tool (which is with the replacement seal) to install the seal assembly. Push seal assembly on shaft until seal faces make light contact.7. Install spring (8) on the carbon seal assembly.8. Put impeller (9) in position on the pump shaft as shown.9. Install washer (11) and bolt (10). Tighten bolt (10) to a torque of 90 15 N m (66 11 lb ft). Hit the bolt with a hammer and tighten again to a torque of 90 15 N m (66 11 lb ft) Make sure the studs for cover (12) are tightened to a torque of 27 4 N m (20 3 lb ft) in the pump housing.10. Put clean engine oil on O-ring seal (13) and install it on cover (12). Put cover (12) in position and install the nuts to hold it to the pump housing.11. Put clean engine oil on the O-ring seal and install it in elbow (14). Put elbow (14) in position on housing assembly (4) and install the bolts to hold the unit together.12. Put clean engine oil on the O-ring seal and install it on the back of housing assembly (4).end by:a) install water pump