807807T Mercruiser INSULATOR, Base

1. Install a floor jack under guard (1) as shown. Remove the bolts that hold the guard in position. Remove guard (1). Weight of the guard is 110 lb. (49.5 kg). 2. Fasten tooling (A) to guard (2) as shown. Remove the bolts that hold the guard in position. Remove guard (2). Weight of the guard is 200 lb. (90 kg). 3. Disconnect wire (3) from the oil pan. 4. Disconnect oil pressure sensing wires (4) from the oil pan. Remove two bolts (5). 5. Remove bolt (6) that holds tube bracket to the oil pan. 6. Remove four bolts (8) from hose elbow and plate (7). Remove hose elbow and plate. Remove O-ring seals. 7. Remove the bolts that hold the oil pan to the engine block. Remove oil pan (9) from the engine block. Weight of the oil pan is 60 lb. (27 kg).Install Oil Pan
1. Put the oil pan (5) in position on the engine block and install the bolts (3) that hold it.2. Install O-ring seal (1) on hose. Install O-ring seal (4) on elbow and plate assembly (2). Put elbow and plate assembly (2) in position on hose and oil pan, then install the four bolts that hold it. 3. Put tube bracket (6) in position on the oil pan and install the bolt that holds it. 4. Connect the two oil pressure sensing wires (8) to the oil pan.5. Install two bolts (7) that hold hose (9) to the oil pan. 6. Connect wire (10) to the oil pan. 7. Install tooling (A) on guard (11) as shown. Put guard (11) in position and install the bolts that hold it. 8. Put guard (12) in position with a floor jack and install the bolts that hold it.Remove Oil Pump
start by:a) remove oil pan 1. Remove the bolts (2) that hold suction bell and tubes (1) to the engine block. 2. Remove O-ring seals (3) from the tubes. Inspect O-ring seals for damage. Make a replacement if necessary. 3. Remove clip (5) and then remove screen (4). Clean the screen if necessary. 4. Remove the bolts (7) that hold the oil pump to the engine block. Remove oil pump (6).Install Oil Pump
1. Put the oil pump (1) in position on the engine block and install the bolts that hold it. 2. Install screen (2) with the clip (3) that holds it. 3. Put a small amount of clean oil on O-ring seals (4). Install the O-ring seals on the tubes. 4. Put tubes (5) in position in the oil pump.5. Put suction bell (6) and support in position on the engine block and install the four bolts that hold it.end by:a) install oil panDisassemble Oil Pump
start by:a) remove oil pump 1. Remove bolts (1) and cover (2). Remove spacer from cover, then remove spring and plunger from pump bore. 2. Remove bolt (4), washer (3) and gear (5) from the pump. 3. Remove bolts (7) then remove shaft assembly (6) from the pump. 4. Remove bolts (8) then remove cover assembly (9) from the pump body. 5. Use tool group (A) to remove bearings (10) from cover assembly (9). 6. Remove shaft and gear assembly (11) from the pump body. 7. Remove bolt and washer from gear (12). Use tool (B) to remove gear (12). 8. Remove shaft and gear assembly (13) from the pump body. 9. Use tool group (A) to remove bearings from pump body bore.Assemble Oil Pump
1. Use tool group (A) to install bearings (2) until they are even with the outside surface of main pump body (1). Install bearings (2) so the junctions in the bearings are 30° 15° from the center line of the bearing bores and toward the oil pump outlet passage as shown. 2. Install shaft and gear assembly (3) in the pump body. Install key in shaft. 3. Install gear (4) on the shaft. Install bolt and washer on the shaft. 4. Install shaft and gear assembly (5) in the pump body. 5. Install bearings (7) in the cover assembly (6) with tool group (A). Install the bearings until they are in position the same distance in from each side of the cover assembly. Install the bearings with the oil holes in the bearings in alignment with the oil holes in the cover assembly and the junctions in the bearings in alignment with the cavity in the cover assembly. 6. Install cover assembly (6) on the pump body. 7. Install shaft assembly (8) on the oil pump body with the two bolts that hold it. 8. Install gear (9) on shaft assembly. Install washer and bolt on gear (9). 9. Install plunger (10), spring (13) and spacer (11) in the pump body. Install cover (12) and the bolts (14) that hold it.end by:a) install oil pump