803607 Mercruiser PLUG-DRAIN

Illustration 1 g00992722
Typical example
(1) Oil seal (2) Ceramic ring and rubber seal (3) Seal assembly (4) Spring Follow these recommendations for installation of the seals:Note: The seal installation tool is part of the replacement seal assembly.
Install oil seal (1) dry. Do not lubricate the sealing lip. Use the correct installation tool and use a slow, even motion to press the seal into the pump housing.
Install the bearing for the auxiliary drive shaft to the depth that is specified in the pump housing. Make sure that the oil hole in the bearing is aligned with the oil passage in the pump housing.
Install the shaft through the oil seal.
Install the shaft's thrust washer.
Lubricate the outside diameter of the ceramic ring and rubber seal (2) with clean water or with 207-1600 Rubber Lubricant.
Orient the polished face of the ceramic ring toward seal assembly (3). Use the installation tool and hand pressure to seat the ceramic ring and the rubber seal into the pump housing.
Remove spring (4) from the seal assembly. Lubricate the inside diameter of the seal assembly with clean water or with 207-1600 Rubber Lubricant.
Use the seal installation tool and hand pressure to install the seal assembly onto the shaft until the face of the seal assembly makes light contact with the face of the ceramic ring and rubber seal.
Install the spring onto the seal assembly. (5) Bearing bore for auxiliary drive shaft ... 75.000 0.055 mm (2.9527 0.0022 inch) (6) Diameter of new auxiliary drive shaft (not shown) ... 74.900 0.015 mm (2.9488 0.0006 inch) (7) Depth of the bearing in the pump housing ... 1.5 0.5 mm (0.06 0.02 inch) (8) Bolt Torque ... 38 4 N m (28 3 lb ft) (9) O-ring seal Lubricate the bore for O-ring seal (9) with glycerin or with engine oil. (10) O-ring seal Lubricate the bore for O-ring seal (10) with engine oil.The water seal must withstand air pressure of the following value. ... 240 kPa (35 psi)The oil seal must withstand air pressure of the following value. ... 103 kPa (15 psi)Type 2
Illustration 2 g00983757
Typical example
(1) Thrust washer Thickness ... 6.000 0.050 mm (0.2362 0.0020 inch) (2) Oil seal (3) Ceramic ring and rubber seal (4) Seal assembly (5) Spring (6) Impeller Diameter of impeller's bore ... 19.000 0.013 mm (0.7480 0.0005 inch) (7) Shaft Shaft's outer diameter for impeller ... 19.050 0.013 mm (0.7500 + 0.0005 inch)Width of shaft's groove for thrust washer ... 6.250 0.050 mm (0.2461 0.0020 inch) (8) Bearing bore for auxiliary drive shaft ... 75.000 0.055 mm (2.9527 0.0022 inch) (9) Diameter of new auxiliary drive shaft (not shown) ... 74.900 0.015 mm (2.9488 0.0006 inch) (10) Depth of the bearing in the pump housing ... 1.5 0.5 mm (0.06 0.02 inch) (11) O-ring seal (12) O-ring seal Assembly Procedure
Follow this procedure for assembly:Note: The seal installation tool is part of the replacement seal assembly.
Install oil seal (2) dry. Do not lubricate the sealing lip. Use the correct installation tool and use a slow, even motion to press the seal into the pump housing.
Install the bearing for the auxiliary drive shaft to the depth that is specified in the pump housing. Make sure that the oil hole in the bearing is aligned with the oil passage in the pump housing.
Install shaft (7) through the oil seal.
Install thrust washer (1).
Lubricate the outside diameter of the ceramic ring and rubber seal (3) with clean water or with 207-1600 Rubber Lubricant.
Orient the polished face of the ceramic ring toward seal assembly (4). Use the installation tool and hand pressure to seat the ceramic ring and the rubber seal into the pump housing.
Remove spring (5) from the seal assembly. Lubricate the inside diameter of the seal assembly with clean water or with 207-1600 Rubber Lubricant.
Use the seal installation tool and hand pressure to install the seal assembly onto the shaft until the face of the seal assembly makes light contact with the face of the ceramic ring and rubber seal.
Install the spring onto the seal assembly.
Lubricate the shaft with engine oil. Place the shaft onto a fixture that will absorb the load and press impeller (6) onto the shaft until the face of the impeller is flush with the face of the shaft.
Lubricate the bore for O-ring seal (11) with engine oil.
Lubricate the bore for O-ring seal (12) with engine oil or glycerin or clean water. Maximum leakage per minute for the water seal at 138 kPa (20 psi) of air pressure ... 20 cc (1.22 cu in)Maximum leakage per minute for the oil seal at 138 kPa (20 psi) of air pressure ... 24 cc (1.46 cu in)