Re: 1999 Johnson 5hp water pump question
Found the procedure:
Gearcase Removal:
1. For safety, disconnect the spark plug lead, then ground it to the cylinder head.
2. Remove the propeller,
3. Drain the gearcase oil. For details, please refer to the procedure in the Maintenance and Tune-Up section.
4. Remove the cover from the starboard side of the exhaust housing in order to access the shift rod, then loosen the shift rod screw.
5. Remove the 2 bolts securing the gearcase to the exhaust housing. Both bolts are threaded up into the exhaust housing from underneath the cavitation plate, one at the front of the plate and the other, toward the rear of the plate.
6. Separate the gearcase assembly from the outboard by pulling carefully straight downward, withdrawing the driveshaft from the exhaust housing as it is lowered. Check the water pump to see if the water tube bushing stayed behind on the tube or if it is contained in the pump housing.
7. Thoroughly inspect the gearcase and exhaust housing for signs of damage. Make sure all mating surfaces are clean and free of debris, corrosion or damage.
Water Pump Removal
1 Remove the gearcase lower unlt from the lntermedlate housmg For detalls, refer to the Gearcase sectlon
2 Remove the nuts securlng the water pump houslng to the lower unlt, then lift the housing from the gearcase
3 Carefully work the lmpeller up and off the drlveshaft
4 Remove the lmpeller key
5 Remove the lmpeller plate Carefully clean all traces of gasket from the top of the gearcase houslng and the bottom of the lmpeller plate
6. If necessary, remove the drlveshaft seal from the top of the water pump housing
7 Thoroughly Inspect the lmpeller, housmg and lmpeller plate for signs of damage or wear and replace, as necessary
To install Waterpump:
8. If removed, lightly coat the outer diameter of a new water pump driveshaft seal using OMC Gasket Sealing Compound or equivalent, then use a suitably sized socket or driver to carefully install the seal into the housing with the lips facing upward. Coat the seal lips using OMC Triple- Guard or equivalent marine grease.
9. Apply a coating of OMC Gasket Sealing Compound or equivalent sealant to both sides of a new impeller plate gasket, then position the gasket and plate onto the gearcase. A small dab of marine grease can be used to help hold the key in position when installing the impeller.
10. Insert the impeller key to the driveshaft keyway, then slide the water pump impeller down the shaft and over top of the key.
11. Slide the water pump housing down the driveshaft until it is just above the impeller. Rotate the driveshaft clockwise while carefully pushing the pump housing down over the impeller and plate.
12. Install the water pump housing nuts and tighten to 36-60 inch Ibs. (4- 7 Nm).
13. Install the gearcase lower unit,
To install Gearcase:
8. Apply a light coating of OMC Moly Lube, or equivalent assembly lubricant to the driveshaft splines.
9. Apply a light coating of RTV sealant to the mating surfaces of the gearcase and the exhaust housing.
10. Apply a light coating of OMC Gasket Sealing Compound, or equivalent sealant to the threads of the 2 gearcase-to-exhaust housing bolts.
11. lnstall the gearcase, while carefully aligning the dowel pins, water tube, water pump seal and driveshaft.
12. lnstall the 2 gearcase mounting screws and tighten to 11-15 ft. Ibs. (1 5-20 Nm).
13. lnstall the propeller and secure using a new cotter pin. For more details, please refer to Propeller under the Maintenance and Tune-Up section.
14. Properly refill the gearcase with lubricant. .
15. Reconnect the spark plug lead.
