0209704 JOHNSON OWNER'S MANUAL, Evinrude

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
B     8T-3034     Water Pump Seal Driver     1    
C     169-5464     Quick Cure Primer     1    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Note: Refer to Disassembly and Assembly, "General Information (Reference Material)" for more information.
Use steel wool to remove the deposits and the corrosion from the shaft.
Do not use sandpaper that will leave visible scratches on the pump shaft.
Inspect the area of the shaft that contacts the carbon seal rubber. Replace the shaft only if one of the following conditions exist in this area: pitting, corrosion and scoring. These conditions can provide a path for the leakage of coolant between the rubber and the pump shaft. If the shaft is polished in this area, this polishing indicates that the carbon seal assembly was spinning on the shaft. Use a fine grit sandpaper on the polished area before you install the new seal assembly.
Use Tooling (C) to clean the shaft and the seal counterbore in the housing.
Illustration 1 g01206688
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.
Apply clean water to the portion of ceramic seal in seal group (10) that is covered by the O-ring seal.
Immerse the carbon seal in seal group (10) in clean water. Install the carbon seal in seal group (10) on the shaft. Use Tooling (B) and hand pressure to push the carbon seal in seal group (10) onto the shaft until the face of the carbon seal makes contact with the ceramic seal face.
Position the spring in seal group (10) on the shaft.
Position impeller (7) on the shaft and install washer (6) and bolt (5) .
Tighten bolt (5) to a torque of 360 50 N m (270 37 lb ft). Hit the head of the bolt with a hammer and tighten the bolt again. Repeat this procedure until there is no change in the bolt torque.
Install a new O-ring seal (8) on the housing. Apply liquid soap to the O-ring seal.Note: Ensure that housing (4) is properly oriented when the housing is installed on the water pump.
Install housing (4) and bolts (9) on the water pump.
Illustration 2 g00605429
Install the coupling and flange (3) .
Install elbow (1). Connect elbow (1) to the tube and water pump (2) .
Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".