806686 Mercruiser BOLT

1. Remove tube assemblies (1) and (3).2. Remove bolts (3) and remove fuel transfer pump (4).3. Put caps for protection of the fuel system on all fuel openings. The following steps are for the installation of the fuel transfer pump.4. Be sure the O-ring seal is in position on fuel transfer pump (4). Put clean engine oil on the O-ring seal.5. Put fuel transfer pump (4) in position and install bolts (3) that hold it in place.6. Remove caps from the fuel openings.7. Install tube assemblies (1) and (2).End By:a. prime the fuel system **See MAINTENANCE MANUAL for this procedure.Disassemble Fuel Transfer Pump
Start By:a. remove fuel transfer pump
Cover (2) is under spring tension. Remove slowly to prevent injury.
1. Carefully remove bolts (1) and cover (2) from the fuel transfer pump. 2. Remove spring (3), valve (4) and O-ring seals (5) from the cover. 3. Remove springs (6) and (7) from the pump housing. 4. Remove sleeve (8) from the pump housing. 5. Remove sleeve (12), piston (16), O-ring seal (11) and piston (9) from sleeve (8). Remove plate (15), valve (10) and seal (14) from piston (9). Remove O-ring seal (13) from sleeve (8). 6. Remove O-ring seal (17) from the pump housing. 7. Push guide (18) through the pump housing and remove guides (23) and (18) together. Remove rod (20), guide (23), O-ring seal (19) and tappet (21) from guide (18). Remove ring (22) from tappet (21). 8. Remove connector (24), valve (26) and seal (25) from the pump housing. 9. Remove plug (30), spring (28), valve (29) and seal (27) from the pump housing.Assemble Fuel Transfer Pump
1. Clean all parts and be sure all passages are open. 2. Be sure the O-ring seal is in position on plug (30) and put 4L7464 Silicone Grease on the O-ring seal. Valves (29), (26) and (10) must be installed as shown, for the pump to operate correctly.3. Install seal (27), valve (29), spring (28) and plug (30) in the pump housing as shown. Tighten plug (30) to a torque of 20 7 N m (15 5 lb.ft.). 4. Be sure the O-ring seal is in position on connector (7) and put 4L7464 Silicone Grease on the O-ring seal.5. Install seal (25), valve (26) and connector (24) in the pump housing as shown. Tighten connector (24) to a torque of 55 10 N m (40 7 lb.ft.). 6. Install the ring on tappet (21). Install tappet (21), O-ring seal (19), guide (23) and rod (20) in guide (18). Put 4L7464 Silicone Grease on O-ring seal (19). Install guides (18) and (23) as a unit in the pump housing as shown. 7. Install O-ring seal (17) in the pump housing and put 4L7464 Silicone Grease on the O-ring seal. 8. Install seal (14), valve (10) and plate (15) in piston (9) as shown. Install piston (9), O-ring seal (11), piston (16) and guide (12) in guide (8) as shown. Install the O-ring seal on guide (8) and put 4L7464 Silicone Grease on O-ring seal (11) and the O-ring seal on guide (8). 9. Install guide (8) in the pump housing as shown. 10. Install springs (6) and (7) in the pump housing as shown. 11. Install O-ring seals (5) and (5) in the cover as shown. Put 4L7464 Silicone Grease on the O-ring seals. 12. Install spring (3) in the cover. Install valve (4) in the cover with the grooves in the valve toward the cover. 13. Put cover (2) in position on the pump housing and install the bolts that hold it in place.End By:a. install fuel transfer pump