36001 Mercury WASHER, WATER PUMP STUDS

start by:a) remove fuel transfer pump1. Remove the cover and O-ring seal from the transfer pump. 2. Remove nut (2), gear (3) and the key from the end of the shaft assembly.3. Remove cage assembly (1) from the shaft assembly.4. Remove the O-ring seals and the ring from the outside of cage assembly (1). 5. Remove the two lip type seals (4) from cage assembly (1). 6. Use tool group (A) to remove bushing from the inside of cage assembly (1).
Use care not to damage the contact surfaces of the body and cover assemblies when the pump is disassembled and assembled.
7. Remove the screws and make a separation of cover assembly (6) from the body assembly (5). 8. Remove bolt (7), the gasket, spring (8) and the plunger from cover assembly (6).9. Remove the lip type seal from cover assembly (6). 10. Remove idler gear (10) and shaft assembly (9) from body assembly (5). 11. If necessary, remove idler gear shaft (11) from body assembly (5). 12. Use tool group (A) to remove the bushing from the body assembly.Assemble Fuel Transfer Pump
See SPECIAL INSTRUCTION Form GMG00578 for instructions to use tool group (B).1. Clean all parts thoroughly before the transfer pump is assembled. 2. Install bearing (2) in body assembly (1) with tool group (A). Make sure the face of the bearing is not beyond surface (D). 3. Install the idler shaft in body assembly (1) until the face of the shaft is .371 .003 in. (9.42 0.08 mm) above surface (D). 4. Put a thin layer of 8S6747 Gasket Sealer (Permatex No. 3) on the outside diameter of seal (4). Install the seal in cover assembly (3) with tool group (A). Make sure dimension (E) is .45 in. (11.4 mm). Make sure the rubber lip of the seal is toward surface (F). Put a light amount of clean diesel fuel on the rubber lip of the seal.5. If necessary, make a replacement of the ferrules in cover assembly (3) so they extend .25 in. (6.35 mm) above surface (F). 6. Install plunger assembly (4), spring (6), the gasket and plug (5). Tighten the plug to a torque of 27 3 lb.ft. (38 4 N m). 7. Put clean oil on shaft assembly (7) and install it in the body assembly. 8. Put clean oil on idler gear (8) and install it in the body assembly.9. Put a thin layer of 8S6747 Gasket Sealer (Permatex No. 3) on the contact surfaces of the cover and body assemblies.
Make sure the Permatex does not get on the inner surfaces of the transfer pump.
10. Install the cover assembly on the body assembly. Install the screws that hold the cover and body assemblies together. After the screws are tightened, make sure shaft assembly (7) is free to turn. 11. Install seals (10) and (11) in the cage assembly with tool group (A). Make sure dimension (G) is .12 in. (3.0 mm). Make sure dimension (H) is .58 in. (14.7 mm). Make sure the rubber lip of seal (11) is toward the face (J) of the cage assembly. Make sure the rubber lip of seal (10) is opposite of face (J). Put a light amount of oil on the rubber lips of seals (10) and (11).12. Install bushing (9) in the cage with tool group (A). 13. Install O-ring seals (12) and the ring on the cage assembly.14. Install the seal guide that is part of tool (B) over the end of the shaft assembly. Install the cage assembly over the shaft assembly. 15. Install the key in the shaft assembly. Install gear (13) and nut (14) on the shaft assembly. Tighten the nut to a torque of 22 5 lb.ft. (28 7 N m). 16. Install the O-ring seal and cover on the transfer pump.end by:a) install fuel transfer pump