817275A08 Mercury REPAIR KIT, Water Pump-Upper

1. Drain the coolant from the aftercooler radiator tank. 2. Disconnect tube (3) from elbow (1) and disconnect elbow (1) from the water pump.3. Disconnect tube (4) from elbow (2). Loosen hose clamp (5).4. Remove bolts (6), clip (8) and elbow (2) from the water pump.5. Disconnect hose (7) from the water pump. 6. Install tooling (A) on water pump (9) and fasten a hoist. Remove bolts (10) and remove auxiliary water hoist. Remove bolts (10) and remove auxiliary water pump (9). The weight of the water pump is 32 kg (70 lb.). 7. If bearing (11) must be replaced, remove the air compressor. See the topic, Remove Air Compressor.8. Remove two bolts (12) and adapter (13). Use tooling (B) and remove bearing (11) from adapter (13). The following steps are for installation of the auxilliary water pump.9. Install the auxiliary water pump in the reverse order of removal.10. If bearing (11) was removed, align the hole in the bearing with the oil hole in adapter (13). Use tooling (B) and install the bearing until it is 1.5 0.5 mm (.06 .02 in.) below the rear surface of adapter (13). After installation, the inside diameter of bearing (11) must be 75.000 0.055 mm (2.9528 .0022 in.)11. Lubricate bearing (11) and the O-ring seal on adapter (13) and water pump (9) with clean engine oil before installation.Disassemble Auxiliary Water Pump (Aftercooler)
START BY:a. remove auxiliary water pump (aftercooler) 1. Remove O-ring seals (3) and (4) from the pump housing.2. Remove the bolts and gear (2) from shaft (1). 3. Remove the bolts and adapter (5) from the pump housing. Remove the O-ring seal from adapter (5). 4. Loosen bolt (6) and the washer that hold impeller (7) to the shaft.5. Use tooling (A) to loosen impeller (7) from the end of the pump shaft. Remove tooling (A), bolt (6), the washer and impeller (7) from the pump shaft and housing. 6. Remove spring (9) from carbon seal assembly (10). Remove carbon seal assembly (10) from the end of shaft (8). 7. Remove the bolts that hold retainer washers (12) to the pump housing. Remove shaft (1) and washers (12) from the pump housing. 8. Remove the bolts that hold the shims and retainer washers (13) to the pump housing. Remove shaft (8), the shims and washers (13) from the pump housing.9. Remove the rubber ring and ceramic seal (11) from the pump housing. 10. Remove lip-type seal (14) from the pump housing. 11. Remove bearing (15) from the pump housing.Assemble Auxiliary Water Pump (Aftercooler)
1. Make sure the oil hole in the bearing is in alignment with the oil passage in housing (1). Use tool group (A) and a press to push the bearing in housing (1) until it is 1.5 0.5 mm (.06 .02 in.) below the surface of housing (1). The inside diameter of the bearing must be 75.000 0.055 mm (2.9528 .0022 in.) 2. Use tool group (A) to install the lip-type seal in housing (1). Make sure the lip of the seal is toward the bearing as shown. Put clean engine oil on the lip of the seal. 3. Install shaft (2) in the pump housing. Install retainer washers (3), the shims and bolts to hold shaft (2) in the pump housing. 4. Put clean engine oil on the bearing in the pump housing, and install shaft (4) and retainer washers (5) over shaft (2). Install the bolts to hold retainer washers (5) to the pump housing.
Clean water only is permitted for use as a lubricant for assembly. Do not damage or put hands on the wear surfaces 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. Install ceramic seal ring (6) in the rubber seal. Put clean water on the rubber seal and ceramic seal ring for lubrication. Use hand pressure and tool (B) to install the seal and seal ring as shown. 6. Remove the spring from carbon seal assembly (7). Put clean water on the inside diameter of the seal assembly for lubrication. Use hand pressure and tool (B) to push seal assembly (7) on the shaft until the seal faces make light contact. 7. Install spring (8) on carbon seal assembly (7). 8. Put impeller (9) in position on the pump shaft as shown. 9. Install the bolt and washer that hold impeller (9) to the pump shaft. Tighten the bolt to a torque of 38 4 N m (28 3 lb. ft.). 10. Install O-ring seal (11) around adapter (10), and put a small amount of clean engine oil or glycerine on it.11. Put adapter (10) in position, and install the bolts to hold it to the pump housing. 12. Put gear (12) in position on shaft (4), and install the bolts to hold gear (12). 13. Install O-ring seals (13) and (14) in the pump housing, and put clean engine oil on the O-ring seals.END BY:a. install auxiliary water pump (aftercooler)