0435501 JOHNSON GEARCASE ASSY., Complete

2. Disconnect vee belts (1) from the fan belt tightener pulley. See Remove Fan Drive And Fan Belt Tightener. 3. Remove the bolts and disconnect the elbow assembly from the radiator.4. Loosen clamp (4) and remove hose (3) and the elbow assembly as a unit from the water pump cover.5. Remove the bolts and elbow (2) from the engine. 6. Remove the bolts and water pump cover (5) from the water pump. 7. Remove four bolts (8) that hold the water pump to the oil cooler bonnet.8. Remove four nuts (7), one bolt and water pump (6) from the front cover.Install Water Pump
1. Make sure all gasket surfaces are clean and free of dirt. 2. Install O-ring seal (2) on water pump (1).3. Put the gasket in position on bonnet (3) and install water pump (1) on the front cover and on the bonnet. 4. Make sure the O-ring seal is in position on the water pump and install water pump housing (5).5. Install the gaskets and elbow (4) as shown.6. Install the gasket and the elbow assembly on the bottom of the radiator.7. Connect hose (6) to the water pump housing, and tighten the clamp that holds it.8. Connect the vee belts on the fan belt tightener pulley. See Install Fan Drive And Fan Belt Tightener.9. Fill the cooling system with coolant. See the Maintenance Guide.Disassemble Water Pump
START BY:a) remove water pump 1. Remove O-ring seal (1) from adapter (2).2. Remove adapter (2) with a screwdriver. Remove the seal from the edge of adapter (2).3. Remove bolt (3) and washer. 4. Remove impeller (4) from the water pump housing with tooling (A). 5. Remove seal assembly (5). Remove ring and seal (6). 6. Remove the bolt and washer that hold gear (7) on the water pump shaft.7. Remove gear (7) with tooling (B).8. Remove bolts and retainer (9).9. Remove O-ring seal (8). 10. Remove shaft (10) and the bearings as a unit.11. Remove bearing (11), spacer (12) and bearing (13) from shaft (10).12. Remove the lip type seal from the gear side of the water pump. Remove the ring and seal from the impeller side of the water pump.Assemble Water Pump
1. Put clean engine oil or glycerine on the lip of seal (1). Install seal (1) with the lip of the seal up as shown with tooling (A). 2. Install bearing (4), spacer (3) and bearing (5) on shaft (2). Install shaft (2) in the pump housing. 3. Install retainer (7) and O-ring seal (8).4. Install gear (6). Install the washer and bolt that hold gear (6) to shaft (2).
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.
5. Put ceramic ring (10) in position in rubber seal (9). Use hand pressure and the tool (which is with the replacement ring) to install the ceramic ring in the housing. 6. Remove spring (12) from seal assembly (11). Use hand pressure and the tool (which is with the replacement ring) to install seal assembly (11). Push the seal assembly on the shaft until the seal face makes light contact.7. Install spring (12) on the shaft. 8. Install impeller (14), the washer and nut (13) that hold the impeller to the pump shaft. Tighten the bolt to a torque of 39 3 N m (28 2 lb.ft.).9. The clearance between the impeller and the adapter must be 0.56 to 1.50 mm (.022 to .059 in.). 10. Put clean engine oil on O-ring seals (15). Install the O-ring seals on adapter (16).11. Install adapter (16) in the pump housing with the notch in alignment with dowel (17).END BY:a) install water pump