803508021 Mercury GASKET

2. Disconnect hose (3) and (6) from the bottom of water pump (5).3. Disconnect heater hose (2) from the valve.4. Remove the clip, bolts and retainers (1) that fasten tube (4) to the water pump and remove tube (4) from the water pump.
Typical Example5. Fasten a nylon strap and a hoist to the water pump.6. Remove bolts (8) that fasten the water pump to adapter (7). Remove bolts (9) that fasten the water pump to the front drive housing and remove the water pump. The weight of the water pump is 40 kg (88 lb.). 7. Remove elbow assembly (10) and the seal from water pump (5).8. Install the water pump in the reverse order of removal.9. Replace all seals and gaskets with new ones.10. Fill the cooling system with coolant and check for leaks. Refer to the Operations And Maintenance Manual for further information.Disassemble Water Pump
Start by:a. remove water pump 1. Remove O-ring seal (4) from the back of housing assembly (3).2. Remove washer (1) that holds shaft assembly (2) in housing assembly (3).
Typical Example3. Remove cover (5) from housing assembly (3). Remove the O-ring seal from cover (5).
Typical Example4. Loosen bolt (7) holding impeller (6) to the pump shaft. Use tooling (A) to loosen impeller (6) from the end of the pump shaft. Remove tooling (A), bolt (7), the washer and impeller (6) from the pump shaft and housing assembly (3).
Typical Example5. Remove spring (9) from seal assembly (8) and shaft assembly (2).6. Use a soft hammer, and push shaft assembly (2) out of seal assembly (8) and housing assembly (3). Remove seal assembly (8) from housing assembly (3). 7. Remove ceramic seal (10) from the rubber ring. Remove the rubber ring from housing assembly (3). 8. Remove seal (11) from the back of housing assembly (3).Assemble Water Pump
1. If necessary, make a replacement of the two filters in the pump housing at location (12).2. If necessary, make a replacement of plug (13) and the seal beneath plug (13).3. Use tooling (A) to install seal (11) into housing (3). Make sure the lip of the seal faces toward the outside as shown. Lubricate the lip seal (11) with clean engine oil. 4. Install shaft assembly (2) into housing (3). Install thrust washer (1) and the bolts to hold shaft assembly (2) in position.
Use clean water as the only lubricant when installing seal group (8). Use care when handling seal group (8) during installation onto pump shaft (2). Touching the wear surfaces of the carbon or ceramic rings can cause contamination or damage. Install the smoothest face of the ceramic ring toward the carbon seal assembly.
5. Put ceramic seal (10) in position in the rubber ring. Use hand pressure and tool (B) to install the ceramic seal.
Typical Example6. Remove the spring from seal assembly (8). Use hand pressure and tool (B) to install the seal assembly. Push the seal assembly on the shaft until the seal faces make light contact.
Typical Example7. Install spring (9) on the carbon seal assembly.8. Put impeller (6) in position on the pump shaft as shown.
Typical Example9. Install the washer and bolt (7). Tighten bolt (7) to a torque of 200 25 N m (150 18 lb. ft.). 10. Make sure the studs for cover (5) are tightened in the pump housing. Torque the three studs to 45 7 N m (33 7 lb ft).11. Install the O-ring seal on cover (5). Lubricate the O-ring seal with clean engine oil. Position cover (5) onto the pump housing. Install and evenly tighten the nuts for cover (5). Torque the nuts holding cover (5) to 27 4 N m (20 3 lb. ft.).End By:a. install water pump