0396409 JOHNSON INTAKE MANIFOLD ASSY.

2. Disconnect the wire from sending unit (1).3. Loosen the hose clamps, and slide hoses (2) and (5) away from elbow (4).4. Remove two bolts (3).5. Remove two bolts (6) that fasten elbow to water pump (8).6. Remove elbow and two gaskets. Check gaskets for wear or damage. Replace if necessary.7. Disconnect the lower radiator hose from water pump (8).8. Remove two bolts (7).9. Remove water pump (8) and the O-ring. Check for wear or damage. Replace if necessary. For installation of the water pump, reverse the removal steps. Fill the cooling system with coolant to the correct level. See the Operation & Maintenance Manual.Disassemble & Assemble Water Pump
Start By:a. remove water pump 1. Remove bolt (15) and the washer. Remove bearing (12) and gear (10) as a unit.2. Use tooling (A), (C) and a press, and remove bearing (12) from gear (10).3. Remove snap ring (8) with tool (B).4. Remove two bolts (1), the washers, cover (14) and gasket (2) from water pump housing (18).5. Loosen bolt (13) approximately 6.4 mm (.25 in). Hit the bolt with a soft hammer to loosen impeller (16) from shaft (9).6. Remove bolt (13), washer (11), impeller (16), spring (3) and seal assembly (4) from shaft (9).7. Remove bearing (7) and shaft (9) as a unit.8. Use tooling (A), (C) and a press to remove bearing (7) from shaft (9).9. Remove ceramic seal (5) and seal (17) from water pump housing (18).10. Use tool (C) to remove lip-type seal (6) from the water pump housing. The following steps are for assembly of the water pump. 11. Install lip-type seal (6) in water pump housing (18) with tool (C). The lip of the seal must be toward the bearings. Put clean engine oil on the lip of the seal.12. Install shaft (9) in bearing (7) with a press.13. Install shaft (9) and bearing (7) as a unit in water pump housing (18).14. Install snap ring (8) with tool (B).
Clean water only is permitted for use as a lubricant for assembly. 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 (5) in position in seal (17). Use hand pressure and tool (D) to install the ceramic ring.16. Remove spring (3) from seal assembly (4). Use hand pressure and tool (D) to install the seal assembly. Push seal assembly (4) on shaft (9) until it makes light contact with ceramic ring (5).17. Install spring (3) on seal assembly (4). Put impeller (16) in position on shaft (9), and install washer (11) and bolt (13) that hold it. Tighten bolt (13) to a torque of 38.0 1.5 N m (28 1 lb ft).18. Put gasket (2) and cover (14) in position on water pump housing (18), and install the two washers and bolts (1) that hold them.19. Install bearing (12) on gear (10) with a press.20. Position gear (10) and bearing (12) as a unit on shaft (9). Install the washer and bolt (15) that hold them together. Tighten bolt (15) to a torque of 97 7 N m (72 5 lb ft).End By:a. install water pump