807653T Mercruiser ALTERNATOR ASSEMBLY

1. Remove three bolts and locks and remove suction bell and tube (1) from oil pump. 2. Remove bolts (2) that hold the elbow and tube assembly to the back of the oil pump.3. Remove four bolts (3) and two locks. Remove the oil pump (4) from the engine.Install Oil Pump
1. Put oil pump (1) in position and install the bolts and locks that hold it.2. Install the bolts that hold elbow (2) and tube assembly to the oil pump. 3. Install suction bell (3) and tube assembly.END BY:a) install oil panDisassemble Oil Pump
START BY:a) remove oil pump1. Remove the idle gear. Remove the bearing from the idler gear with tooling (B). 2. Remove the bolt and washer from the oil pump drive gear. Remove drive gear (1) with tooling (A). Remove the key from the pump shaft.3. Remove bolts (2) from the pump body. 4. Remove body (7), two gears (6), keys and spacer (3) from the pump.5. Remove two shafts (4) and the gears.6. Remove bolt (5), the cover and the valve assembly from the pump. 7. Remove the bearings from the oil pump body assembly and the scavenge pump body assembly with tooling (B). Assemble Oil Pump
1. Install the bearings in the scavenge pump body assembly with tooling (A) as follows:a) Put bearings (1) in position on the inside of the scavenge pump body assembly with the chamfer on the bearing toward the outside of the pump body. Install the bearing until it is .060 in. (1.52 mm) below the inside machined surface of the scavenge pump body assembly. Make sure the joints in the bearings are at an angle of 30° 15° from the center line through the bores in the scavenge pump body and toward the outlet passage of the pump. The outlet passage has a cavity between the bearing bores. 2. Install the bearings in oil pump body assembly with tooling (A) as follows:a) Put bearings (2) in position on the inside of the oil pump body assembly with the chamfer on the bearings toward the outside of the pump body. Install the bearings until they are even with the outside of the pump body. Make sure the joints in the bearings are at an angle of 30° 15° from the centerline through the bearing bores and toward the outlet passage of the pump. The outlet passage has a cavity between the bearing bores.3. Check the condition of the relief valve. Check the condition and specifications for all the parts of the oil pump before it is assembled. See OIL PUMP (2P1785) in SPECIFICATIONS.4. Put clean engine oil on all the parts of the oil pump. 5. Install pressure relief valve (3), cover (4) and bolt (5) in the oil pump body assembly. 6. Install gears and shafts (6) in the oil pump body assembly.7. Install spacer (7) and the two keys in shafts (6). 8. Install two gears and scavenge pump body assembly (8).9. Install key (9), drive gear (11), the washer and bolt (10). Tighten the bolt to a torque of 32 5 lb.ft. (43 7 N m).10. Install the bearing in the idler gear with tooling (A) until it is even with the outside surface of the gear.11. Install the idler gear.
The oil pump must turn freely by hand after it is assembled.
END BY:a) install oil pump