Mercury Marathon - 30 Reference manual

94-5 494Printed in U.S.A. - 1 -
No. 94-5
Water Pump Base Replacement - 30/40
Mariner and Mercury
19941/230/40
Serial Number
US 0G053314 thru 0G071765
Outboards listed, may have had the lower seal in the
water pump base damaged during manufacturing.
Damage to this seal could, after prolonged operating
time allow water to enter the gear housing causing
damage.
OWNER NOTIFICATION:
Astherewereonlyasmallnumberofregisteredunits
atthetimethisproblemwasdetected,acustomerlet-
ter will not be issued.
Please contact the owners of any affected outboards
thatyour dealership mayhave delivered andarrange
to have the water pump base replaced.
CORRECTION:
IMPORTANT:Removeanyburrsonthedriveshaft
using 320 grit carborundum cloth prior to remov-
ing the water pump impeller.
1. Remove the gear housing assembly and disas-
semble the water pump components to gain ac-
cess to the water pump base. Refer to 30/40 Ser-
vice Manual 90-826148.
2. Withthegearhousingsecuredintheuprightposi-
tion, remove the vent plug.
IMPORTANT: Protect the gasket surfaces of the
water pump area of the gear housing with a shop
towel when removing the water pump base.
3. Use a locking pliers to pull, or two screw drivers
to pry the water pump base out of the gear hous-
ing (Figure 1).
b
a
a - Water Pump Base
b - Vent Plug
Figure 1. Water Pump Base Removal
NOTE: If you are not able to remove the water pump
base as described, remove the water pump base
along with the drive shaft as outlined in the service
manual.
4. Apply a light coating of 2-4-C Marine Lubricant
with Teflon (92-825407A12) onto a new o-ring
and install the o-ring into the groove around the
replacement water pump base (Figure 2).
52825
a
b
a - O-Ring
b - Water Pump Base
Figure 2. O-Ring Installation.

94-5 494 - 2 -
5. Pushthe newwaterpumpbaseintogearhousing
(Figure 3).
IMPORTANT: When installing water pump cover,
make sure drive shaft is centered in opening of
pump cover and pump cover screws are torqued
in sequence shown. The drive shaft should be
freetobe turnedby handandnot rubonthe water
pump cover.
6. Assemblethe waterpumpcomponents(with new
gaskets), install the vent plug, and install gear
housing as outlined in 30/40 Service Manual
90-826148.
52832
a
b
c c
cc
a - Water Pump Base
b - Vent Plug
c - Bolts [Torque 60 lb. in. (6.8 N·m) ]
Figure 3. Water Pump Base Installation
7. Markarepairedoutboardwithawhitepaintdoton
theupperrearcorneroftheexhaustcover(Figure
4).
REWORK/PART IDENTIFICATION:
Outboards with in the serial number range listed that
have been reworked at the factory are identified by:
A blue dot sticker applied on the outboard serial
number label of the shipping carton.
A white dot painted on the upper rear corner of
the exhaust cover (Figure 4).

a
a - White Paint Dot
Figure 4. Rework Identification

94-5 494
- 3 -
DEALER SERVICE STOCK:
Replacethe water pump baseforany of the following
service assemblies/accessory kits in your stock that
have a date code prior to “03 MAR 94”.
Part Number Description
46-821307A2 Water Pump Base
1682-821306A8 Gear Housing (Short-
Black)
1682-821306A6 Gear Housing (Long-
Black)
1682-821306A10 Gear Housing (LL-Long
Black)
1682-821306A9 Gear Housing (Short-
Gray)
1682-821306A7 Gear Housing (Long-
Gray)
1682-821306A11 Gear Housing (LL-Long
Gray)
1682-821306A12 Gear Housing (Basic-
Black)
1682-821306A13 Gear Housing (Basic-
Gray)
824072A3 Drive Shaft Extension
Kit (Black)
824072A4 Drive Shaft Extension
Kit (Gray)
DEALER OUTBOARD INVENTORY:
Affected outboards in dealer inventory MUST BE re-
worked prior to customer delivery.
WARRANTY:
Outboards:
Complete a warranty claim listing:
Outboard serial number.
Qty. 1 p/n 46-821307A2 Water Pump
Base
Qty. 1 p/n 27-822189 Gasket - Water
Pump Cover
Qty. 1 p/n 27-822217 Gasket - Water
Pump Face Plate
1.3 hours labor
Labor Rate Code: NJC
Failure Code: 613 00
Dealer Service Stock:
Complete a warranty claim listing:
The part number of the service assembly/acces-
sory kit that you are replacing the water pump
base on. Multiple part numbers can be listed on a
single claim.
Qty. 1 p/n 46-821307A2 Water Pump
Base
Qty. 1 p/n 27-822189 Gasket - Water
Pump Cover
Qty. 1 p/n 27-822217 Gasket - Water
Pump Face Plate
0.3 hours labor
Labor Rate Code: NJC
Failure Code: 613 00
Outboards/Dealer Service Stock:
US and Canada: Return water pump base assem-
blies with warranty claim.
International: Hold water pump base for inspection/
disposal by a Marine Power International technical
representative.