803535003 Mercury PLUNGER

2. Disconnect hose assemblies (3) and (4) from fuel transfer pump (1). Disconnect tube assembly (2) from fuel transfer pump (1). 3. Remove two bolts (5) and two bolts (6) from fuel transfer pump (1). Remove fuel transfer pump (1) and the seal O-ring from the engine oil pump. The following steps are for the installation of the fuel transfer pump. Inspect all O-ring seals for wear or damage and replace if necessary. 4. Put fuel transfer pump (1) and the seal O-ring in position on the engine oil pump. Install two bolts (5) and two bolts (6) in fuel transfer pump (1). 5. Connect tube assembly (2) to fuel transfer pump (1). Connect hose assemblies (3) and (4) to fuel transfer pump (1).6. Turn the fuel supply valve, located on the fuel tank, to the "On" position.7. Prime the fuel system prior to starting the engine. Refer to the topics "Priming the Fuel System and Priming Procedure (Dry Start)" in the 5130B Excavator Operation and Maintenance Manual.Disassemble Fuel Transfer Pump
Start By:a. remove fuel transfer pump 1. Pull drive coupling (2) from the pump shaft.2. Remove O-ring seal (1) from the pump. 3. Remove relief valve cap (6), washer (5), spring (4) and poppet valve (3) from the pump bracket assembly. 4. Remove two bolts (7), and remove pump head (8) from plate (9). 5. If necessary, remove valve (10) from head (8). 6. Remove plate (9) from the pump casing.7. Remove gasket (11) and the O-ring seal from the opposite side of plate (9).8. If necessary, remove the bushings from plate (9). 9. Remove gear assembly (12) and shaft assembly (13) from the pump bracket and casing (14). 10. Remove casing (14) and sleeves (15) from pump bracket (16).11. Remove the O-ring seal from casing (14). 12. Remove outer seal (17) and inner seal (18) from bracket (16).13. If necessary, remove the bushings from bracket (16).Assemble Fuel Transfer Pump
1. Use Tool (A) to install the inner and outer lip seals in bracket (1). Make sure the lips of the seals are in the position shown at assembly.
Use an arbor press to install bushings (2) in the bracket. The bushings must be installed in one continuous stroke of the press to prevent damage to the bushings. Failure to do so could result in pump failure.
2. Use Tool (A) and an arbor press, and install bushings (2) in bracket (1) in one continuous stroke. Install the bushings until they are 1.5 mm (.06 in.) below the surface of the bracket. The inside diameter of the bushings must be 12.736 mm (.5014 in.) after installation. 3. Install sleeves (4) in bracket (1).4. Install O-ring seal (5) in casing (3), and put casing (3) over sleeves (4) on bracket (1). 5. Install gear assembly (6) and shaft assembly (7) in the bracket and casing.
Use an arbor press to install bushings (8) in the plate. The bushings must be installed in one continuous stroke of the press to prevent damage to the bushings. Failure to do so could result in pump failure.
6. Use Tool (A) and an arbor press, and install bushings (8) in plate (9) in one continuous stroke. Install the bushings until they are 1.5 mm (.06 in.) below the surface of the plate. The inside diameter of the bushings must be 12.736 mm (.5014 in.) after installation. 7. Install O-ring seal (10) in plate (9), and put plate (9) in position on the pump casing. 8. Use Tool (A) to install the valve in head (11) until it makes contact with the shoulder in the bore. Make sure the spring on the valve is toward the inside before it is installed.
When head (11) is installed, be sure the drain hole (weep hole) is open. Failure to do so could result in pump failure.
9. Put gasket (12) and head (11) in position on the plate, and install the two bolts that hold the pump together. 10. Install poppet valve (13), spring (14), and the washer and relief valve cap (15) in the pump. 11. Install O-ring seal (16) around the pump.12. Install drive coupling (17) on the pump shaft.End By:a. install fuel transfer pump