0584508 JOHNSON POWER PACK ASSEMBLY

3. Remove air compressor water line (3) from the engine.4. Disconnect hose (2) from the water pump elbow.5. Loosen the hose clamps for the short hose behind hose (2).6. Loosen hose clamps (6) and push the hose down away from the pump.7. Remove two bolts (5) and the two bolts (1). Remove water pump (4) and elbow from the engine as a unit. The weight is 35 lb. (16 kg).Install Water Pump
1. Inspect the O-ring seal for the water pump. Install a new seal if needed. 2. Put water pump (1) and the elbow in position as a unit. Make sure the gasket for the elbow is in position and install the bolts that hold the elbow and water pump.3. Connect the water pump elbow to the cylinder block with the short hose and tighten the hose clamps.4. Move the bottom hose up on the water pump and tighten the clamps.5. Connect the heater hose to the water pump.6. Install the air compressor coolant line.7. Install the fan guard.8. Fill the cooling system with coolant to the correct level.Disassemble Water Pump
start by:a) remove water pump 1. Remove cover (3) and gasket from water pump (1).2. Remove elbow (2) and gasket from water pump (1). 3. Loosen bolt (5) .25 in. (6.35 mm). Hit (tap) the bolt with a soft hammer to remove impeller (4) from the shaft. 4. Remove spring and seal assembly (7) from shaft (6). 5. Turn the water pump over and remove bolt (8) and lockwasher.6. Remove O-ring seal (9) from the housing. 7. Use tooling (A) to remove gear (11) and bearing (10) from the water pump.8. Remove bearing (10) from gear (11). 9. Remove snap ring (12) with tool (B). 10. Remove bearing (14) and shaft (13) as a unit. 11. Use tool (C) and a press to remove bearing (14) from the shaft. 12. Remove the ceramic ring and seal (15) from the housing. 13. Remove the lip type seal (16) from the housing with tooling (D).Assemble Water Pump
The seal must be installed with the lip toward the bearings. 1. Install the lip type seal in housing (1) with tooling (A) to the bottom of the seal counterbore. Put a thin layer of engine oil on the lip of the seal. 2. Use a press to install shaft (2) in bearing (3). 3. Install the shaft and bearing (3) in housing (1). 4. Install snap ring (4) in the housing with tool (B). 5. Install bearing (5) on gear (6).
When gear (6) is installed, make sure the pins on the gear engage the holes in the shaft.
6. Put gear (6) and bearing in position on the shaft and install washer and bolt. 7. Install O-ring seal (7) on the housing.
Clean water only is permitted for use as a lubricant to make assembly easier. 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.
8. Put the ceramic ring (8) in position in the rubber seal. Use hand pressure and tool (which is with the replacement ring) to install the ceramic ring and rubber seal. 9. Remove the spring from the seal assembly (9). Use hand pressure and the tool (which is with the replacement ring) to install the seal assembly. Push seal assembly on the shaft until seal faces make light contact. 10. Install spring (10) on the seal assembly. 11. Put impeller (11) in position on the shaft. 12. Install washer and bolt (12). Tighten the bolt to a torque of 28 1 lb.ft. (39 1 N m).13. Install a new gasket and cover (13) on the housing. 14. Install a new gasket and elbow (14) on the housing.end by:a) install water pump