805016A 1 Mercruiser FLAME ARRESTOR

1. Drain the cooling system.2. Disconnect the coolant hose from elbow (3).3. Remove two tube assemblies (2).4. Remove the bolts that hold elbow (3) to the water pump, and remove the elbow.5. Remove the bolts that hold elbow (1) to the water pump.6. Remove the bolts and retainers that hold elbow (1) to the tube assembly, and remove the elbow. 7. Remove the bolts and adapter assembly (4) from the front drive housing. 8. Remove O-ring seals (6) and (7) from adapter assembly (4).9. If necessary, remove bearing (5) from the adapter assembly. 10. Fasten a hoist and tooling (A) to water pump (8). Remove the bolts and the water pump from the front drive housing. The weight of the water pump is 25 kg (55 lb).11. Remove the O-ring seal from the water pump.Install Auxiliary Water Pump
1. Put O-ring seal (1) in position on the water pump. Put clean engine oil on the O-ring seal.2. Fasten a hoist and tooling (A) to water pump (2). Put the water pump in position on the front drive housing, and install the bolts that hold it. 3. If the bearing was removed from adapter assembly (3), align the hole in the bearing with the oil hole in the adapter assembly. Install the bearing with a press and tool (B). Install the bearing until it is 1.5 0.5 mm (.06 .02 in) below surface (X). The inside diameter of the bearing must be 75.000 0.055 mm (2.9528 .0022 in) after installation. 4. Put O-ring seals (4) and (5) in position on adapter assembly (3). Put clean oil on the O-ring seals.5. Put the adapter assembly in position on the front drive housing, and install the bolts that hold it. 6. Make sure the O-ring seal is in position on tube assembly (6). Put elbow (7) in position on the tube assembly, and install the retainers and bolts to hold it in place.7. Put the gasket in position between elbow (7) and the water pump, and install the bolts and nuts that hold the elbow to the water pump.8. Put the O-ring seal in position on the back of the water pump, and install elbow (9).9. Install two tube assemblies (8).10. Connect the coolant hose to elbow (9).11. Fill with coolant to the correct level.End By:a. install air compressorDisassemble Auxiliary Water Pump
Start By:a. remove auxiliary water pump 1. Remove O-ring seals (3) and (4) from the pump housing.2. Remove the bolts and gear (2) from shaft (1). 3. Remove the bolts and adapter (5) from the pump housing. Remove the O-ring seal from adapter (5). 4. Loosen bolt (6) holding impeller (7) to the shaft.5. Use tooling (A) to loosen impeller (7) from the pump shaft. Remove tooling (A). Remove the washer, bolt (6), and impeller (7) from the pump shaft and housing. 6. Remove spring (9) from carbon seal assembly (10). Remove carbon seal assembly (10) from the end of shaft (8). 7. Remove the bolts that hold retainer washers (12) to the pump housing. Remove shaft (1) and washers (12) from the pump housing. 8. Remove the bolts that hold the shims and retainer washers (13) to the pump housing. Remove shaft (8), the shims and washers (13) from the pump housing.9. Remove the rubber ring and ceramic seal (11) from the pump housing. 10. Remove lip-type seal (14) from the pump housing. 11. Remove bearing (15) from the pump housing.Assemble Auxiliary Water Pump
When installing bearing (15) make sure the lubrication hole in the bearing is aligned with the oil passage in the pump housing.
1. Position bearing (15) on the pump housing making sure the oil passages are in aligned. Use tool group (A) and a press to push the bearing into the pump housing until. Bearing (15) should be 1.5 0.5 mm (.06 .02 in.) below the surface of the pump housing. The inside diameter of the bearing must be 75.000 0.055 mm (2.9528 .0022 in.). 2. Position seal (14) into the pump housing. Make sure the lip of seal (14) faces toward bearing (15) as shown. Install seal (14) with a press and tooling (A). Use clean engine oil to lubricate seal (14). 3. Install shaft (8) in the pump housing. Install the shims, bolts and retainer washers (13). 4. Lubricate bearing (15) with clean engine oil. Install shaft (1) and retainer washers (12). Install the bolts into retainer washers (12).
Use clean water as the only lubricant when installing seal group into the pump housing. Use care when handling the seal group during installation. Touching the wear surfaces of the carbon or ceramic rings can cause contamination or damage. Install the smoothest face of the ceramic ring toward the carbon seal assembly.
5. Install ceramic ring (11) into the rubber seal. Lubricate ceramic ring (11) with water. Use hand pressure and tool (B) to install the seal and seal ring into the housing as shown. 6. Remove spring (9) from carbon seal assembly (10). Put clean water on the inside diameter of the seal for lubrication. Use hand pressure and tool (B) to push carbon seal (10) onto shaft (8) until the faces of seals (11) and (10) make contact. 7. Install spring (9) into carbon seal (10). 8. Put impeller (7) in position on the pump shaft as shown. 9. Install the bolt and washer that hold impeller (9) to the pump shaft. Tighten the bolt to a torque of 38 4 N m (28 3 lb. ft.). 10. Install the O-ring seal onto adapter (5). Use clean engine oil to lubricate the O-ring seal.11. Install adapter (5) onto the pump housing. 12. Put gear (2) in position on shaft (1). Install the bolts to hold gear (2). 13. Install O-ring seals (3) and (4). Lubricate the O-ring seals with clean engine oil.End By:a. install auxiliary water pump