807259A 2 Mercruiser COVER ASSEMBLY

1. Remove O-ring seal (2) from the body.2. Remove elbow (1). 3. Remove O-ring seal (4) from elbow (1).4. Remove elbow (1) and gasket from bell (3). 5. Remove screen assembly (5) and gasket from bell (3). 6. Remove diffuser (6) from the relief valve. 7. Remove relief valve (7) from the body.
There is spring force behind cover (8).
8. Remove cover (8) from the relief valve body.9. Remove washer (9), spring (10) and valve spool (11) from the relief valve body. 10. Remove baffle (12) from the cover.11. Remove cotter pin (13).
Make sure the top of the nut is not above the end of the shaft. Damage to the nut, shaft or both can be the result when tooling (A) is used to loosen the gear from the taper.
12. Loosen nut (14) approximately 1/8 in. (3.18 mm). 13. Use tooling (A) to loosen gear (15) from the taper on the shaft. Remove tooling (A) and gear (15). Remove the key that holds the gear to the shaft. 14. Remove cover (16) from the body. 15. Remove bearings (17) from cover (16) with tooling (B) and a press. 16. Remove shaft assembly (19).17. Remove body (18). 18. Remove spacer (21) and shaft assembly (20) as a unit. 19. Remove key (22) from the shaft assembly. Remove spacer (21) from shaft assembly (20). 20. Remove gears (24) from body (23).21. Remove body (23) from cover (25). 22. Remove bearings (26) from cover (25) with tooling (B) and a press.Assemble Oil Pump
1. Make sure all the parts of the oil pump are clean. Inspect all parts for damage and make replacements if needed. Put clean oil on the parts during assembly.
Install the bearings in the cover so the oil holes in the bearings are in alignment with the oil holes in the cover and so the bearing junctions (joints) are 45° from the centerline of the cover as shown in illustration B29676X1.
2. Use a press and tooling (A) to install bearings (1) in the cover. The bearings must be installed .06 .01 in. (1.6 0.3 mm) below surface (X). If dowels (2) were removed, the new dowels must be installed .25 .02 in. (6.4 0.5 mm) above surface (X). 3. Put body (3) in position on cover (4). If dowels (5) and (6) were removed, dowel (5) must be installed .31 in. (7.9 mm) above the surface of the body and dowel (6) must be installed .25 in. (6.4 mm) above the surface of the body. 4. Install gears (7) in body (3). If dowels (11) were removed, the new dowels must be installed .25 .02 in. (6.4 0.5 mm) above surface (Y). The dowels must be installed from the side of the spacer with the chamfers. 5. Put shaft assembly (10) in position in spacer (8). Install key (9) in the shaft assembly. 6. Put spacer (8) and shaft assembly (10) in position on the body. Make sure the key in the shaft is in alignment with the groove in the gear in body (3). 7. Install shaft assembly (11) in the spacer and gear. 8. Put body (12) in position on the spacer.
Install bearings (13) in the cover so the bearing junctions (joints) are in the position shown in illustration A37393X2.
9. Use a press and tooling (A) to install bearings (13) in cover (14). The bearings must be installed .06 .01 in (1.6 0.3 mm) below surface (Z). If the dowels were removed, the new dowels must be installed .25 .02 in. (6.4 0.5 mm) above surface (Z). 10. Install cover (14) on the body. Make sure the bolts with the "X" mark on them are installed in the holes with the dowels. 11. Install key (18) in the shaft.12. Make an alignment of the groove in gear (17) with the key. Put gear (17) in position on the shaft. Install washer (16) and nut (15). Tighten the nut to a torque of 100 lb. ft. (135 N m). 13. Tighten the nut more if necessary and install cotter pin (20).14. Install baffle (19) with locks and bolts. 15. Install valve spool (24), spring (23), washer (22) and cover (21) in the relief valve body.16. Install relief valve (25) on the body. 17. Install diffuser (26) on the relief valve. 18. Put gasket (28) and screen assembly (27) in position in bell (29). 19. Install O-ring seal (31) on elbow (30).20. Install gasket (32) and elbow (30) on bell (29). Install the locks and bolts that hold them together. 21. Install elbow (30) and the bell on the body. Use the locks and bolts to hold it in place.
Before installation, lubricant must be in the oil pump and it must turn freely.
end by:a) install oil pump