0435351 EVINRUDE PISTON ASSY., 0.030 in. o.s.

1. Remove breather tube (1) from the engine.2. Remove bolts (2) that hold the elbow to the water temperature regulator housing. Remove elbow (3) from the water pump. Loosen the two clamps and slide hose (8) free of the water pump. Remove bolts (7) from the bonnet. On later engines a line from the top of the water pump to the coolant filter must be disconnected at the water pump.3. Remove seven long bolts (4) that hold the water pump to the timing gear cover. Remove water pump (5). Some of the bolts hold cover (6) to timing gear cover. 4. To install, put water pump (5) into position in the timing gear cover. Install the bolts that hold it.5. Put hose (8) in position on the water pump. Tighten the clamps that hold it. Install the bolts that hold the elbow to the water temperature regulator housing. Install the bolts that hold bonnet (9) to the water pump.6. Install the breather tube on the engine.Disassemble And Assemble Water Pump
Start By:a. remove water pump The water pump seal can be replaced without removing the water pump from the engine.An intermittent leakage of a small amount of coolant from the hole in the water pump housing is not an indication of a water pump seal failure. This is required to provide lubrication for the seal. Replace the water pump seal only if a large amount of leakage or a constant flow of coolant is observed draining from the water pump housing.1. Remove O-ring seal (3) from adapter (4). Remove the adapter from housing (7). Remove the O-ring seal from the outside of the adapter.2. Remove bolt (1) and washer (2). Use tooling (A) to remove impeller (6) from shaft (13).3. Remove spring and seal (5) from the shaft.4. Remove four bolts (16) from retainer (12) that hold the shaft assembly to the pump housing. Remove O-ring seal (18) from housing (7).5. Remove gear and shaft assembly (17) from the housing. Remove bolt (15), retainer (14), and retainer (12) from the shaft assembly.6. Use a press to remove shaft (13) from the gear. Remove bearing (9), spacer (10), and bearing (11) from the shaft.7. Remove lip-type seal (8) from the housing.8. Turn the housing over, and remove ceramic ring (20) and seal (19) from the housing. The following steps are for the assembly of the water pump.9. Use 6V1541 Quick Cure Primer and clean shaft (13) and the seal counter bore in the pump housing.10. Install bearing (9), spacer (10), and bearing (11) on shaft (13).11. Put retainer (12) and gear (17) on the shaft assembly. Install retainer (14) and bolt (15) on the shaft.12. Use tooling (B) to install lip-type seal (8) in housing (7). Install seal with the lip toward the inside of the housing. Put a small amount of clean SAE 30 oil on the lip of the seal.13. Install a new O-ring seal (18) on the housing.14. Put gear and shaft assembly (17) in position in the housing. Install bolts (16) that hold retainer (12) to the housing.
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.
15. Put ceramic ring (20) in position in seal (19). Use hand pressure and tool (C) to install the ceramic ring in the housing.
Avoid contaminating the seal faces with grease or oil. Also, avoid stretching the rubber seal during installation.
The carbon seal assembly must rotate with the water pump shaft after installation.16. Separate spring and seal (5). Use hand pressure and tool (C) to install the seal on the shaft of gear and shaft assembly (17). Push the seal on the shaft until the seal faces make light contact. Install the spring on the shaft.17. Put impeller (6) in position on the shaft. Install washer (2) and bolt (1) that hold the impeller. Tighten the bolt to a torque of 39 3 N m (29 2 lb.ft.).18. Install the O-ring seal on the outside diameter of adapter (4). Put a small amount of clean SAE 30 oil on the O-ring seal.19. Install O-ring seal (3) on the adapter.20. Put adapter (4) in position on the housing.End By:a. install water pump