0384293 EVINRUDE CYLINDER AND CRANKCASE ASSEMBLY

1. Disconnect water pipe (3) and tubing (4) from the water pump. Remove bolts (1) and water pump (2). Remove and inspect the water pump gasket.2. Install the auxiliary sea water using the reverse procedures of Step 1.Disassemble Auxiliary Sea Water Pump
Start By:a. remove auxiliary sea water pump 1. Put identification marks on the pump housings (1) and separate them. Remove gasket (2) from between the housings. 2. Remove locknut (4), washer and gear (3).3. Remove retainer ring (5) with tool (A). 4. Remove nut (6) from the impeller shaft.5. Use tool (B) and a shop press to remove the impeller shaft from the impeller.6. Remove impeller (7) from the housing. 7. Remove water seal assembly (8) and make a separation of the water seal components. Inspect each component. 8. Use tool (B) and a shop press to remove the impeller shaft completely out of the pump housing. 9. Remove key (9) and shim pack (11) behind it. Remove retainer ring (10) from bearing tool (C).10. Remove key (13) spacer (12) and retainer ring, remove retainer ring also with tool (C). 11. Use tooling (D) and a shop press and push shaft out of bearings (14) and spacer (15). 12. Remove lock (17) and remove gear assembly (16). 13. Use tooling (D) and a shop press to push gear from the shaft. 14. Use tooling (D) and a shop press to push shaft out of bearings (18) and spacer (19). 15. Remove ceramic ring (20) if damaged.16. Remove slinger (21) from the pump housing. 17. Remove seal (22) from the pump housing.Assemble Auxiliary Sea Water Pump
1. Put the intermediate shaft (1) in tool (A) as shown.2. Heat bearing (2) to a temperature of 135° C (275° F) and install it on the shaft. 3. Install spacer (3). Heat bearing (4) to a temperature of 135° C (275° F) and install it on the shaft. 4. Heat gear (5) to a temperature of 135° C (275° F) and install it on the shaft. 5. Install shaft assembly into the pump housing and install lock (6). 6. Install seal (7) in the pump housing.7. Install seal with the lip away from the impeller. 8. Install slinger (8) in the pump housing.
Do not damage or put hands on the wear surface of the ceramic ring. Clean water only is suggested as a lubricant for assistance at installation.
9. Install ceramic ring (9) in the pump housing. 10. Install retainer ring (10) on the shaft with tool (B). 11. Heat bearings (11) to a temperature of 135° C (275° F). Install bearing (13), spacer (12) and bearing (11) on the shaft. 12. Install shaft assembly in the pump housing. Install spacer (15) and key (16).13. Install retainer ring (14) with tool (B). 14. Install gear (17), washer and nut (18). Tighten nut to a torque of 45 5 N m (33 4 lb.ft.). 15. Soak the lower portion of water seal assembly (21) in hot water and install it on the shaft. Install shim pack (19) and key (20). 16. Install spring (23) and retainer (22) [part of water seal assembly (21)]. 17. Install impeller (25) and locknut (24). Tighten the locknut to a torque of 34 to 41 N m (25 to 30 lb.ft.). 18. Check the clearance between impeller and pump housing. Shims should be added just until the impeller is clear of the housing. 19. Install gasket (26) on impeller housing. 20. Install impeller housing (27) on the other pump housing making sure the identification marks are in alignment. 21. Check the impeller again.End By:a. install auxiliary sea water pump