76965A 3 Mercruiser STARTER MOTOR ASSEMBLY, COMPLETE

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-0510 Driver Gp 1
C 248-3311 Holding Fixture 1
D 476-2902 Spanner Wrench 1
E 8H-0663 Bearing Puller Gp 1
F 8H-8581 Feeler Gauge 1
G 325-5756 Seal Tool 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g06379817
Use Tooling (E) and a suitable press to install bearing assembly (16) on pump shaft (11).
Install bearing cone (22) on the pump shaft.
Install spacer (21) and bearing cups (21) on the pump shaft.
Install bearing cone (19) on the pump shaft.
Illustration 2 g06379835
The splined end of the pump shaft is marked to indicate either RH threads or LH threads on pump shaft (11). Install bearing locknut (15). Use Tooling (D) on the bearing locknut. Tighten the bearing locknut to a torque of 300 30 N m (221 22 lb ft).Note: The torque wrench must be 90 degrees to Tooling (D).
Install set screws (14) and tighten to a torque of 8 1 N m (70.8 8.9 lb in).
Illustration 3 g06379897
Use Tooling (A) and a suitable press to install lip seal (18) in bearing housing (2). Ensure that the lip is toward the outside.Note: Install the lip seal dry. Install the lip seal within 2 minutes of removal from the shipping sleeve.
Illustration 4 g06379930
Lubricate pump shaft (11) with clean engine oil. Install the pump shaft in bearing housing (2). Install retainer (10). Install socket head bolts (9) and tighten to a torque of 12 3 N m (106 27 lb in).
Illustration 5 g06379946
Use a press and Tooling (G) to install a new seal assembly (12) over shaft (11) and into housing (2). Ensure that the outer shell of the seal is fully seated in the housing.
Lubricate pump shaft (11) on bearing housing (2) with clean engine oil. Position impeller (8) on the pump shaft.
Illustration 6 g06379954
Place bearing housing (2) on impeller (8). Use a suitable press and press pump shaft (11) into the impeller. Install the impeller so the dimension between the impeller and the pump shaft is 0.0 0.15 mm (0.0 0.006 inch).
Illustration 7 g06379992
Install O-ring seal (7) on bearing housing (2). Lubricate the O-ring seal with clean engine oil.
Position bearing housing (2) in housing (4). Install washers and bolts (6) finger tight.
Illustration 8 g01036084
Tighten the bolts in a numerical sequence to a torque of 50 9 N m (35 7 lb ft).
Use Tooling (F) and measure the gap between the impeller and the pump housing. The minimum gap between the impeller and the pump housing is 0.20 mm (0.008 inch).
Illustration 9 g06376145
Install the O-ring seal on plug (5). Install the plug-in housing (4). Tighten the plug to a torque of 177 7 N m (131 6 lb ft).
Install the O-ring seal on plug (3). Install the plug-in bearing housing (2). Tighten the plug to a torque of 8 1 N m (6 1 lb ft).
Install the O-ring seal on plug (1). Install the plug-in bearing housing (2). Tighten the plug to a torque of 17 1 N m (151 9 lb in).
Install water pump filter (4) in bearing housing (3).End By:
Install the water pump.