860616 Mercruiser EXTENSION HARNESS (7 METERS)

1. Release the pressure in the cooling system. Drain the coolant from the radiator. The capacity of the cooling system is 44 liters (11.4 U.S. gal).
Typical Example2. Loosen the hose clamp, and disconnect hose (1) from the water pump.3. Loosen hose clamp (3) that holds hose (2) to the elbow. 4. Loosen hose clamps (5), and slide hose (4) down and off of the water pump. 5. Remove bolt (6) and the bolts which hold water pump (8) to the timing gear cover. Separate the water pump from the timing gear cover and elbow (7). Remove the o-ring seal from the water pump housing. The following steps are for the installation of the water pump.6. Check the condition of the o-ring seal in the water pump housing. If the seal is worn or damaged, use a new part for replacement. Install the o-ring seal in the water pump housing.7. Put water pump (8) in position in the timing gear cover and elbow (7). Install the bolts that hold it.8. Connect hose (4) to the water pump. Tighten two hose clamps (5) that hold it.9. Tighten hose clamp (3) that holds hose (2) to the elbow.10. Connect hose (1) to the water pump.11. Fill the cooling system with coolant to the correct level. See the Operation & Maintenance Manual for the correct filling procedure.Disassemble Water Pump
Start By:a. remove water pump1. Be sure the outside of the water pump is thoroughly clean prior to disassembly. 2. Remove cover (1) and the gasket from water pump (2). 3. Loosen bolt (3) approximately 6.35 mm (.25 in). Hit the end of the bolt with a soft faced hammer to loosen impeller (4) from the taper on the shaft. Remove bolt (3), the washer and impeller (4) from the shaft. 4. Remove seal group (5) from shaft (6). 5. Turn the water pump housing over. Remove bolt (7) and the washer. Remove bearing (8) and drive gear (9) as a unit. 6. Using tool (A), tool (C) and a press, remove drive gear (9) from bearing (8). 7. Using tool (B), remove retaining ring (10) from the pump housing. 8. Remove bearing (11) and shaft (6) as a unit. 9. Using tool (A) and a press, remove bearing (11) from shaft (6). 10. Remove the ceramic ring and seal (12) from the pump housing. 11. Remove seal (13) from the pump housing with tool (C).Assemble Water Pump
1. Install a new lip seal in the pump housing with tool (A). Install the sal with the lip facing toward the drive gear side of the housing and until it makes contact with the counterbore in the housing. Do not lubricate the sealing lip. 2. Using a press, install shaft (1) in bearing (2). Install the shaft until the flange makes contact with the bearing. 3. Install shaft (1) and the bearing in pump housing (3). 4. Install retaining ring (4) in the pump housing with tool (B). 5. Using a press and tool (A), install bearing (5) on drive gear (6). Install the bearing until it makes contact with the shoulder on the drive gear. 6. Put drive gear (6) and the bearing in position in the pump housing and on shaft (1). Install the bolt and washer that hold the drive gear to the shaft. Tighten the bolt to a torque of 97 7 N m (71 5 lb ft).
Only clean water is permitted as a lubricant for installation of the carbon ring and the ceramic ring. 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.
7. Put ceramic ring (7) in position in the rubber seal in the pump housing. Using the tool which comes with the replacement ring, install the ceramic ring only with hand pressure. 8. Remove the spring from seal assembly (8). Using the tool which comes with the replacement ring, install the seal assembly only with hand pressure. Install the seal assembly until it makes light contact with the ceramic ring. 9. Install spring (9) over the shaft in the water pump. Put impeller (10) in position on the shaft, and install the washer and bolt that hold it. Tighten the bolt to a torque of 38 1.5 N m (28 1 lb ft).10. Install a new gasket and the cover on the water pump.End By:a. install water pump