866459J00 Mercruiser HOUSING, Driveshaft - Basic

2. Remove oil line (3) and elbow (2). 3. Remove the two bolts that hold the fuel transfer pump in place. Remove fuel transfer pump (4) and gasket (5).Install Fuel Transfer Pump
1. Install fuel transfer pump (1) and gasket (2) on the engine. 2. Connect two oil lines (3) to the fuel transfer pump.Disassemble Fuel Transfer Pump
Start By:a. remove fuel transfer pump 1. Remove the two bolts and clamps that hold the service meter in position. Remove service meter (3) from the fuel transfer pump. Remove the O-ring seal from the service meter.2. Remove the bolts that hold body (1) to cover (2). Remove the cover from the body. 3. Remove plug (3), spring (5), and plunger (6) from cover (2). Remove seal (4) from plug (3). 4. Remove gear (7) from body (1). 5. Remove nut (8) and gear (9) from shaft (11). Remove the key from the shaft.6. Remove O-ring seal (10) and shaft (11) from body (1). 7. Use a press, as shown, to remove gear (12) from shaft (11). 8. Use tool (A) to remove bearing (13) from the end of body (1). Remove the two lip type seals that are behind bearing (13). 9. Remove dowel (14), ferrule (15), and valve assembly (17) from the body. Use tooling (B) to remove bearing (16).Assemble Fuel Transfer Pump
1. Install dowel (1) in the body so that the dowel is even with, or a maximum of 0.3 mm (.010 in) below surface (3).2. Install ferrule (2) in the body so the ferrule extends 5.6 mm (.22 in) above the surface. 3. Install valve assembly (4) in the body. Make sure the top of the valve assembly is approximately 0.4 mm (.015 inch) below the surface. Stake the valve assembly in three places to hold the valve assembly in place.4. Use tooling (A) to install bearing (5) in the body. Install the bearing so that the top of the bearing is 0.8 mm (.03 in) below the surface. 5. Use tooling (A) to install lip type seal (6) with the lip up, as shown. Install the seal so that dimension (X) is 24.6 mm (.97 in).6. Use tooling (A) to install lip type seal (7) with the lip down, as shown. Install the seal so that dimension (Y) is 14.2 mm (.56 in).7. Put clean diesel fuel on the lips of lip type seals (6) and (7).8. Use tooling (A) to install bearing (8) in the body. Install the bearing so that the bearing is even with the end of the body, as shown. 9. Heat gear (9) to a maximum temperature of 316°C (600°F). Install gear (9) on shaft (10) so that dimension (Z) is 49.7 mm (1.957 in). 10. Install O-ring seal (11) on the body. Put clean engine oil on the seal.11. Install shaft (10) and key (13). Install gear (12) and nut (14). Tighten nut (14) to a torque of 30 7 N m (22 5 lb ft). 12. Put 8H5137 Permatex #2 Form A Gasket on the outside diameter of lip type seal (19). Use tooling (A) to install the lip type seal in the cover. Install the seal with the lip in as shown. Install the seal to a depth of 19 mm (.75 in) from the outside surface of the cover. Remove the excess gasket material from the bore.13. Put clean diesel fuel on the lip of seal (19).14. Install plunger (18) and spring (17) in the cover. Put seal (16) in position on plug (15). Install plug (15) in the cover. Tighten the plug to a torque of 37 4 N m (27 3 lb ft). 15. Put 7M7260 Liquid Gasket Material on surface (23) of the body. Make sure the gasket material does not enter the pump. Install gear (21).16. Install cover (20) on body (22). Make sure the shaft will turn freely after the cover is installed. 17. Make sure O-ring seal (26) is in position on the service meter. Put clean diesel fuel on the O-ring seal. Install service meter (24) on the fuel transfer pump. Make sure the dial on the service meter is toward bolt (25).End By:a. install fuel transfer pump