896163A01 Mercury PUMP KIT, Trim

3. Loosen the hose clamp and remove hose (1) from elbow (5).4. Remove two bolts (2) and two bolts (3). Loosen hose clamp (4), and remove elbow (5) from the hose and the water pump.5. Loosen the two hose clamps, and slide hose (8) away from the water pump.6. Remove two bolts (6) and remove water pump (7) from the timing gear cover. The following steps are for installation of the water pump.7. Check the O-ring seal on the water pump, and make a replacement if necessary, Put water pump (7) in position on the timing gear cover. Install two bolts (6) that hold it.8. Put hose (8) in position on the water pump, and tighten the hose clamps that hold it.9. Put a new gasket on elbow (5), and position it on the hose and water pump. Install two bolts (2) and two bolts (3) that hold it. Tighten hose clamp (4).10. Install hose (1) on the elbow, and tighten the hose clamp that holds it.11. Fill the cooling system to the correct level with coolant. See the Maintenance Guide.12. Install the guard assembly on the left side of the engine.Disassemble Water Pump
Start By:a. remove water pump1. Remove bolt (15) and the washer. Remove bearing (12) and gear (10) as a unit.2. Use tooling (A), (C) and a press, and remove bearing (12) from gear (10).3. Remove snap ring (8) with tool (B).4. Remove two bolts (1), the washers, cover (14) and gasket (2) from water pump housing (18).5. Loosen bolt (13) 6.4 mm (.25 in). Hit the bolt with a soft hammer to loosen impeller (16) from shaft (9).6. Remove bolt (13), washer (11), impeller (16), spring (3) and seal assembly (4) from shaft (9).7. Remove bearing (7) and shaft (9) as a unit.8. Use tooling (A), (C) and a press to remove bearing (7) from shaft (9).9. Remove ceramic seal (5) and seal (17) from water pump housing (18).10. Use tool (C) to remove lip-type seal (6) from the water pump housing.Assemble Water Pump
1. Install lip-type seal (6) in water pump housing (18) with tool (C). The lip of the seal must be toward the bearings. Put clean engine oil on the lip of the seal.2. Install shaft (9) in bearing (7) with a press.3. Install shaft (9) and bearing (7) as a unit in water pump housing (18).4. Install snap ring (8) with tool (B).
Clean water only is permitted for use as a lubricant for assembly. Do not damage or put hands on the wear surface of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal assembly.
5. Put ceramic ring (5) in position in seal (17). Use hand pressure and tool (D) to install the ceramic ring.6. Remove spring (3) from seal assembly (4). Use hand pressure and tool (D) to install the seal assembly, push seal assembly (4) on shaft (9) until it makes light contact with ceramic ring (5).7. Install spring (3) on seal assembly (4). Put impeller (16) in position on shaft (9), and install washer (11) and bolt (13) that hold it. Tighten bolt (13) to a torque of 38.0 1.5 N m (28 1 lb ft).8. Put gasket (2) and cover (14) in position on water pump housing (18), and install the two washers and bolts (1) that hold them.9. Install bearing (12) on gear (10) with a press.10. Position gear (10) and bearing (12) as a unit on shaft (9). Install the washer and bolt (15) that hold them together. Tighten bolt (15) to a torque of 97 7 N m (72 5 lb ft).End By:a. install water pump