0437078 EVINRUDE DECAL SET, Johnson

1. Turn fuel supply valve (1) to the "Off" position. 2. Put a suitable container in position under fuel transfer pump (3) to contain the oil for disposal.3. Mark and identify tube and hose assemblies for installation purposes. Disconnect two hose assemblies (4) and (5) from fuel transfer pump (3). Disconnect tube assembly (6) from fuel transfer pump (3). Cap and plug all openings to prevent fuel loss.4. Remove four bolts (2), and remove fuel transfer pump (3). 5. Remove O-ring seal (7) from the fuel transfer pump. The following steps are for the installation of the fuel transfer pump. 6. Check O-ring seal (7) for wear or damage, and replace if necessary. Install O-ring seal (7) on the fuel transfer pump. Lubricate O-ring seal (7) with clean engine oil. 7. Put fuel transfer pump (3) in position. Install four bolts (2).8. Connect two hose assemblies (4) and (5) to fuel transfer pump (3). Connect tube assembly (6) to fuel transfer pump (3). 9. Turn the fuel supply valve to the "On" position. Prime the fuel system. Refer to the Operation & Maintenance Manual for the correct procedure on priming the fuel system.Disassemble Fuel Transfer Pump
Start By:a. remove fuel transfer pump 1. Pull drive coupling (2) from the fuel transfer pump shaft.2. Remove O-ring seal (1) from the fuel transfer pump. 3. Remove cap (6), seal washer (5), spring (4) and relief valve poppet (3) from the fuel transfer pump bracket assembly. 4. Remove bolts (7), and remove fuel transfer pump head (8) from plate (9). 5. If necessary, remove check valve (10) from fuel transfer pump head (8). 6. Remove plate (9) from the fuel transfer pump casing.7. Remove gasket (11) and the O-ring seal from the opposite side of plate (9).8. If necessary, remove the bearings from plate (9). 9. Remove gear assembly (12) and shaft assembly (13) from the fuel transfer pump bracket and fuel transfer pump casing (14). 10. Remove fuel transfer pump casing (14) and sleeves (15) from fuel transfer pump bracket (16).11. Remove the O-ring seal from fuel transfer pump casing (14). 12. Remove outer seal (17) and inner seal (18) from fuel transfer pump bracket (16).13. If necessary, remove the bearings from fuel transfer pump bracket (16).Assemble Fuel Transfer Pump
1. Use Tool (A) to install the inner and outer lip seals in fuel transfer pump bracket (1). Make sure the lips of the seals are in the position shown at assembly. Put clean engine oil on the lips of the seals.
Use an arbor press to install bearings (2) in the fuel transfer pump bracket. The bearings must be installed in one continuous stroke of the press to prevent damage to the bearings.
2. Use Tool (B) and an arbor press, and install bearings (2) in bracket fuel transfer pump (1) in one continuous stroke. Install the bearings until they are 1.5 mm (.06 in) below the surface of the fuel transfer pump bracket. The inside diameter of the bearings must be 12.736 mm (.5014 in) after installation. 3. Install sleeves (4) in fuel transfer pump bracket (1).4. Install O-ring seal (5) in fuel transfer pump casing (3), and put fuel transfer pump casing (3) over sleeves (4) on fuel transfer pump bracket (1). 5. Install gear assembly (6) and shaft assembly (7) in the fuel transfer pump bracket and the fuel transfer pump casing.
Use an arbor press to install bearings (8) in the plate. The bearings must be installed in one continuous stroke of the press to prevent damage to the bearings.
6. Use Tool (B) and an arbor press, and install bearings (8) in plate (9) in one continuous stroke. Install the bearings until they are 1.5 mm (.06 in) below the surface of the plate. The inside diameter of the bearings must be 12.736 mm (.5014 in) after installation. 7. Install O-ring seal (10) in plate (9), and put plate (9) in position on the fuel transfer pump casing. 8. Use Tool (A) to install the check valve in head (11) until it makes contact with the shoulder in its bore. Make sure the spring on the check valve is toward the inside before it is installed.
When head (11) is installed, be sure the drain hole (weep hole) is open).
9. Put gasket (12) and fuel transfer pump head (11) in position on the plate, and install the two bolts that hold the fuel transfer pump together. 10. Install the relief valve poppet (13), spring (14), and the seal washer and cap (15) in the fuel transfer pump. 11. Install O-ring seal (16) around the fuel transfer pump, and put clean engine oil on it.12. Install drive coupling (17) on the fuel transfer pump shaft.End By:a. install fuel transfer pump