811490 Mercruiser GASKET SET-ENGINE OVERHAUL

2. Disconnect heater hose (3) from the water pump.3. Loosen two clamps (4) and slide the small hose back on the bonnet assembly.4. Disconnect the inlet hose assembly from the bottom of the water pump.5. Remove two bolts (1). There is one short bolt and one long bolt.6. Remove two bolts (2) and water pump (5) from the timing gear cover. Check the condition of the O-ring seal in the water pump. If the seal has damage, use a new part for replacement.Install Water Pump
1. Install a new O-ring seal in the groove on the water pump. Put the water pump in position in the timing gear cover. Install the four bolts that hold it.2. Connect the inlet hose to the bottom of the water pump. 3. Slide hose (1) on the water pump and tighten the two clamps that hold it.4. Connect heater hose (2) to the water pump.5. Install the left fan guard and the left guard assembly on the machine.6. Fill the cooling system with coolant to the correct level. See MAINTENANCE MANUAL.Disassemble Water Pump
Start By:a. remove water pump 1. Remove cover (1) from water pump (2). 2. Loosen bolt (3) on impeller (4) 6.35 mm (.25 in.). Hit the bolt with a soft hammer to remove the impeller from the shaft. 3. Remove spring and seal assembly (5) from the shaft (6). 4. Turn the housing over and remove bolt and washer (7). Remove bearing (8) and gear (9) as a unit. 5. Use tool (A), tooling (C) and a press to remove bearing (8) from gear (9). 6. Remove snap ring (10) with tool (B). 7. Remove bearing (11) and shaft (6) as a unit. 8. Use tool (A) and a press to remove bearing (11) from the shaft. 9. Remove the ceramic ring and seal (12) from the housing. 10. Remove the lip seal (13) from the housing with tool (C).Assemble Water Pump
1. Install the lip-type seal in the water pump housing with tool (A). The lip of the seal must be toward the bearings. Put clean engine oil on the lip of the seal. 2. Install shaft (1) in bearing (2) with a press. 3. Install shaft (1) and bearing (2) in the housing as shown. 4. Install snap ring (3) with tool (B).
Clean water only is permitted for use as a lubricant for assembly. 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 (4) in position in the rubber seal. Use hand pressure and the tool (which is with the replacement ring) to install the ceramic ring. 6. Remove the spring from seal assembly (5). Use hand pressure and the tool (which is with the replacement ring) to install the seal assembly. Push seal assembly (5) on the shaft until it makes light contact with ceramic ring (4). 7. Install spring (6) as shown. Put impeller (7) in position on the shaft, and install the washer and bolt that hold it. Tighten the bolt to a torque of 39 1 N m (28 1 lb.ft.). 8. Put the gasket and cover (8) in position on the water pump housing, and install the washers and bolts (9) that hold them. 9. Install bearing (10) on gear (11) with a press. 10. Align pins (12) on gear (11) and the holes in shaft (1). Put the gear and bearing in position on the shaft, and install the washer and bolt that hold them together.End By:a. install water pump