808235 Mercruiser FUEL SENSOR

1. Remove the cotter pin, nut, and bolt (2) that hold the splined coupling in position.2. Slide the coupling (1) toward the oil pump drive until the drive shaft (3) for the oil pump is free.3. Remove the bolts that hold the tube (5) for the suction bell to the oil pump and oil pump drive. Remove the tube.4. Remove the bolts (4) and locks that hold the oil pump (6) to the oil pan. Remove the oil pump.Install Oil Pump
1. Put the tube for the suction bell in position on the oil pump. Install the bolts that hold it. 2. Put the oil pump (3) in position on the oil pan. Install the bolts and locks that hold it.3. Install the bolts that hold the tube for the suction bell to the oil pump drive.4. Slide the splined coupling (1) on the drive shaft (2) for the oil pump so it connects the drive shafts for the oil pump and oil pump drive.5. Install the bolt, nut, and cotter pin that hold the coupling in position.end by: a) install oil pan (front section only)Disassemble Oil Pump
start by: a) remove oil pump 1. Remove bolts (1) and bell (2) from the oil pump. Remove bolts (3) that hold the cover to the bell. 2. Remove cover (5) and screen (4) from bell (2). Clean the screen. 3. Remove the bolts that hold the relief valve to the pump body. Remove relief valve body (8), spring (7), and plunger (6).4. Remove bolts (9) that hold the oil pump together. 5. Remove main pump body (10) from scavenge pump body (11).6. Remove gear (12) and shaft assembly (15) from body (10).7. Remove gear (17), key (16), and spacer (13) from the shaft assembly.8. Remove two gears (14) from body (11).9. Remove the bearings from gear (12) and two gears (14).10. Remove the bearings from the two bodies.Assemble Oil Pump
Put a small amount of oil on all inner parts of the oil pump before assembly. 1. Install the bearings in the two bodies with tooling (A). Make sure the bearings are .030 .010 in. (0.76 0.25 mm) below the inside surface of the bodies. 2. Install the bearings in gears (4) with tooling (B). Make sure the bearings are .030 .010 in. (0.76 0.25 mm) below the surface of the gears. 3. Install the bearings in gear (2) with tooling (B). Make sure the bearings are .016 .010 in. (0.41 0.25 mm) below each surface of the gear.4. Install spacer (3), key (6) and gear (8) on shaft assembly (7).5. Install gear (2) and shaft assembly (7) in body (1).6. Install two gears (4) in body (5).7. Put body (5) in position on body (1). Install the bolts that hold the bodies together. 8. Install the spring and the plunger in the relief valve body. Install the relief valve (12) on the oil pump.9. Put the screen in position in bell (10). Install the cover and bolts (11) that hold it on the bell.10. Install the bell and bolts (9) that hold it on the oil pump. Pump must turn freely by hand after assembly.end by: a) install oil pump