830153A09 Mercury DECAL SET, Mercury 5

Typical Example2. Disconnect fuel line (1).3. Remove two bolts (2). Remove the fuel transfer pump. The following steps are for the installation of the fuel transfer pump.4. Be sure the o-ring is in place on the fuel transfer pump. Lightly lubricate o-ring with clean engine oil before assembly. Install the fuel transfer pump. Install two bolts (2).5. Connect fuel line (1).6. Connect fuel supply line to fuel transfer pump.Disassemble & Assemble Fuel Transfer Pump
Start By:a. remove fuel transfer pump 1. Remove two bolts and washers (1), and remove cover (2).2. Remove o-ring (3) from cover (2).3. Remove idler gear (4) from the pump housing.4. Position idler gear (4) and idler shaft (5) in a press. Press idler shaft (5) from idler gear (4).
Before removing input shaft (7) and fuel transfer gear (11) from pump housing, be sure that no burrs exist on the input shaft. If the shaft has burrs it could scratch the pump housing and damage it.
5. Install tooling (A), and remove drive gear (8). Remove fuel transfer gear (11) and input shaft (7) from pump housing.6. Position input shaft (7) and fuel transfer gear (11) in a press. Press input shaft (7) from fuel transfer gear (11).7. Remove bearing (6) from the pump housing.8. Remove two lip seals (9) and (10) from the pump housing.
There is spring force against plug (12). To prevent personal injury, release the spring force by holding the plug in position as it is being removed.
9. Carefully remove plug (12) and its o-ring from cover (2) to release the spring pressure.10. Remove spring (13) and pressure relief valve (14) from cover (2). The following steps are for the assembly of the fuel transfer pump.11. Install pressure relief valve (14), and spring (13) into cover (2). Install the o-ring on plug (12), and install it in cover (2).12. Install lip seal (10) into the pump housing maintaining Dimension W. Dimension W is the distance from the top side of lip seal (10) to the surface of the pump housing after assembly. Refer to illustration C44817P1.13. Install lip seal (9) into the pump housing maintaining Dimension X. Dimension X is the distance from the bottom side of lip seal (9) to the surface of the pump housing after assembly. Refer to illustration C44817P1.14. Install bearing (6) into the pump housing.15. Install fuel transfer gear (11), and input shaft (7) into the pump housing.16. Position the pump housing into a press, and install drive gear (8) onto input shaft (7) maintaining Dimension Y. Dimension Y is the distance between the outside face of drive gear (8) and input shaft (7). Refer to illustration C44817P1.17. Position idler gear (4) into a press, and install idler shaft (5).18. Install the assembled idler gear (4) and idler shaft (5) into the pump housing. Maintain Dimension Z between the surface of the pump housing and the top surface of idler gear (4). Refer to illustration C44817P1.19. Install o-ring (3) into cover (2). Install cover (2) onto the pump housing, and secure with bolts and washers (1).End By:a. install fuel transfer pump