809159 Mercruiser BOLT

1. Drain the coolant from the cooling system. Loosen the fan belt tightener. Radiator guard was removed for photo illustration.2. Remove the fan belts.3. Remove upper elbow (not shown), tube assembly (2), elbow (3), heater hose (1) and cover (4). 4. Remove four bolts (7) that connect the water pump to the flange.5. Remove four nuts (5) and one bolt (not shown) that hold the water pump to the timing gear cover. Remove water pump (6).Install Water Pump
1. Check all O-ring seals and gaskets. If damaged, use new parts for replacement.2. Install O-ring seal (2).3. Put water pump (1) in position, and install the bolt and four nuts that hold the water pump to the timing gear cover. Install the four bolts that hold the water pump to the flange. 4. Install cover (6), elbow (5), tube assembly (4), upper elbow (not shown) and heater hose (3).5. Install the fan belts. Tighten the fan belts to the correct tension. See the Maintenance Guide.6. Fill the cooling system with coolant to the correct level. See the Maintenance Guide.Disassemble Water Pump
START BY:a. remove water pump 1. Remove O-ring seal (1) from adapter (2).2. Remove adapter (2) with a screwdriver. Remove the seal from the edge of adapter (2).3. Remove bolt (3) and washer. 4. Remove impeller (4) from the water pump housing with tooling (A). 5. Remove seal assembly (5). Remove ring and seal (6). 6. Remove the bolt and washer that hold gear (7) on the water pump shaft.7. Remove gear (7) with tooling (B).8. Remove bolts and retainer (9).9. Remove O-ring seal (8). 10. Remove shaft (10) and bearings as a unit.11. Remove bearing (11), spacer (12) and bearing (13) from shaft (10).12. Remove lip-type seal from the gear side of the water pump. Remove ring and seal from the impeller side of the water pump.13. Use 6V1541 Quick Cure Primer to clean shaft (10) and the seal counterbore in the pump housing.Assemble Water Pump
1. Install seal (1) as shown with tooling (A). Put clean engine oil on the lip of seal (1). 2. Install bearing (4), spacer (3) and bearing (5) on shaft (2). Install shaft (2) in the pump housing. 3. Install retainer (7) and O-ring seal (8).4. Install gear (6). Install washer and bolt that hold gear (6) to shaft (2).
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.
5. Put ceramic ring (10) in position in the rubber seal (9). Use hand pressure and the tool (which is with the replacement ring) to install the ceramic ring in the housing.
Avoid contaminating the seal faces with grease or oil. Also, avoid stretching the rubber seal during installation.
The carbon seal assembly must rotate with the water pump shaft after installation.6. Remove spring (12) from seal assembly (11). Use hand pressure and the tool (which is with the replacement ring) to install the seal assembly (11). Push seal assembly on the shaft until the seal face makes light contact.7. Install spring (12) on the shaft. 8. Install impeller (14) and the washer and nut (13) that hold the impeller to the pump shaft. Make an air pressure test of the seal at 20 psi (140 kPa). 9. Put clean engine oil on the O-ring seals (15). Install the O-ring seals on adapter (16).10. Install adapter (16) in the pump housing with the notch in alignment with dowel (17).END BY:a. install water pump