0435558 JOHNSON FUEL PUMP ASSY.

Torque converter oil cooler removed for photographic purposes.2. Disconnect three fuel lines (1) from the fuel transfer pump.3. Remove the four bolts that fasten fuel transfer pump (2) to the oil pump and remove the fuel transfer pump. Do not remove the two bolts that hold the fuel transfer pump sections together.4. Check the condition of the O-ring seal on the face of the fuel transfer pump. Install a new seal if necessary. Lubricate the seal and the drive spline with clean engine oil.5. Install the fuel transfer pump in the reverse order of removal.6. Open the fuel supply valve at the fuel tank.Disassemble Fuel Transfer Pump
Start By:a. remove fuel transfer pump 1. Pull drive coupling (2) from the pump shaft.2. Remove O-ring seal (1) from the pump. 3. Remove cap (6), seal washer (5), spring (4) and relief valve poppet (3) from the pump bracket assembly. 4. Remove bolts (7), and remove pump head (8) from plate (9). 5. If necessary, remove check valve (10) from head (8). 6. Remove plate (9) from the 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 pump bracket and casing (14). 10. Remove casing (14) and sleeves (15) from pump bracket (16).11. Remove the O-ring seal from casing (14). 12. Remove outer seal (17) and inner seal (18) from bracket (16).13. If necessary, remove the bearings from bracket (16).Assemble Fuel Transfer Pump
1. Use tool group (A) to install the inner and outer lip-type seals in 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 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 (1) in one continuous stroke. Install the bearings until they are 1.5 0.05 mm (.06 0.02in.) below the surface of the bracket. The inside diameter of the bearings must be 12.736 mm (.5014 in.) after installation. 3. Install sleeves (4) in bracket (1).4. Install O-ring seal (5) in casing (3), and put casing (3) over sleeves (4) on bracket (1). 5. Install gear assembly (6) and shaft assembly (7) in the bracket and 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 0.05 mm (.06 0.02in.) 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 pump casing. 8. Use tool group (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 head (11) in position on the plate, and install the two bolts that hold the pump together. 10. Install the relief valve poppet (13), spring (14), and the seal washer and cap (15) in the pump. 11. Install O-ring seal (16) around the pump, and put clean engine oil on it.12. Install drive coupling (17) on the pump shaft.End By:a. install fuel transfer pump