811564 Mercruiser PISTON/PIN (STD.) 7.4L BRAVO I/II

1. Disconnect wire harness (1).2. Disconnect hoses (2) from the fuel transfer pump. Put caps or plugs in all fuel openings to keep dirt out of the fuel system. 3. Remove bolts (4), fuel transfer pump (3) and the gasket from the fuel injection pump housing.Install Fuel Transfer Pump
1. Install the gasket and fuel transfer pump (1) on the fuel injection pump housing. Install the bolts that hold the fuel transfer pump in position. 2. Connect wire harness (2). Connect two hoses (3) to the fuel transfer pump.Disassemble Fuel Transfer Pump
START BY:a. remove fuel transfer pump 1. Remove the bolts, clamps and tachometer drive group (3) from cover (4).2. Remove bolts (1) and make a separation of cover (4) from body (2). 3. Remove lip type seal (6) from the cover. Remove plug (5), seal, spring and plunger (bypass valve) from the cover. 4. Remove nut (10) from shaft (7). Remove gear (9) and key (11).5. Remove shaft (7) and gear (8) as a unit. Remove gear (8) from drive shaft (7) with a press.6. Remove idler gear (12). 7. Remove bushing (14), two lip type seals and the bottom bearing from pump body (2).8. Remove check valve (13).Assemble Fuel Transfer Pump
1. Install bushing (4) in body (3) with tooling (A). The bushing must not be extended above the (gear) surface of the body.2. Install the check valve in the body with tooling (A).3. Install lip seal (5) with tooling (A). Install the seal until it is 24.6 0.5 mm (.97 .02 in.) from the bottom surface of body (3) and with the lip toward bushing (4) as shown.4. Install lip type seal (6) with tooling (A). Install the seal until it is 14.2 0.5 mm (.56 .02 in.) from the bottom surface of body (3) and with the lip away from seal (5) as shown.5. Install bearing (7) in body (3) with tooling (A). The bearing must be even with the surface of the pump body. 6. Heat gear (8) to a maximum temperature of 316°C (600°F). Install gear (8) on shaft (11) until dimension (X) is 49.71 mm (1.957 in.).7. Install the drive shaft and gear in body (3). Install key, gear (10) and nut (9). Tighten the nut to a torque of 30 7 N m (22 5 lb.ft.).8. Install idler gear (12) in body (3).9. Install lip type seal (2) with tooling (A). Install the seal until it is 19.05 mm (.750 in.) from the top surface of cover (1) and with the lip toward the inside as shown. 10. Install plunger (14) (bypass valve), spring (15) and seal plug (13) in pump cover (1). Tighten plug (13) to a torque of 28 4 N m (21 3 lb.ft.).
Do not let the liquid gasket enter the pump.
11. Put 7M7260 Liquid Gasket Material on the surface of cover (1). Install cover (1) on the pump body. The drive shaft must turn freely after the bolts that hold the transfer pump together are tightened. 12. Inspect O-ring seal (17) for wear or damage and make a replacement if necessary.13. Install tachometer drive group (16) on cover (1). Install the clamps and the bolts that hold it. Tighten the bolts to a torque of 14 3 N m (10 2 lb.ft.).END BY:a. install fuel transfer pump