POWER STEERING
72951
PUMP
8
A
Index
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Torque Specifications
Precautions
!
CAUTION
Fastener Location
Lb. Ft. Lb. In.
N·m
Do not operate engine without cooling water be-
ingsuppliedtowaterpickuppumporwaterpump
impeller will be damaged and subsequent over-
heating damage to engine may result.
Crankshaft Pulley To
Torsional Damper
35
42
Torsional Damper To
Crankshaft
60
81
41
27
Pump Mounting
Bracket To Engine
30
!
WARNING
Recirculation Pump
Pulley
Always disconnect battery cables from battery
before working on engine to prevent fire or explo-
sion.
240
Early Style
Power
Steering
Large
20-25
27-34
!
CAUTION
Hose Fittings
Early Style
Power
Steering
Hose Fittings
Do not pry on power steering pump or alternator
when adjusting belt tension. Serious damage
may result.
Small
96-108 11-12
31
Later Style
Power Steering
Hose Fittings
23
Tools/Sealants
Description
Pulley Installer
Part Number
91-93656A1
92-34227-1
Quicksilver Perfect Seal
Pulley Removal Tool
(Kent-Moore)
J-25034
Kent-Moore Special Tools
29784 Little Mack
Roseville, MI 48066
(313) 574-2332
Index
90-823226--1 996
POWER STEERING - 8A-1
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Power Steering Pump and Components
(Exploded View)
6
16
22
23
21
3
4
22
20
19
23
1
18
17
12
9
11
2
10
14
5
7
8
15
13
22
23
14
72951
24
1 - Power Steering Pump Assembly
2 - Stud
13- Hose, Pump To Fluid Cooler
14- Clamp
3 - Cap
4 - Spacer
5 - Brace
15- Hose, Control Valve To Fluid Cooler (Fitting On One End)
16- Mounting Bracket, Cast
17- Bolt
6 - Spacer
18- Spacer (Barrel Shaped)
19- Lockwasher
20- Nut (For Item 17)
7 - Lockwasher
8 - Bolt, Pump To Brace
9 - Pulley
21- Nut (For Item 21)
10- Belt
22- Lockwasher
11- O-Ring, High Pressure Hose Fitting
12- Hose, High Pressure (Fittings on Both Ends)
23- Bolt To Cylinder Block
24- Power Steering Cooler
Index
8A-2 - POWER STEERING PUMP
90-823226--1 996
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Serpentine Belt Routing
BRAVO WITH POWER STEERING
ALPHA WITH POWER STEERING
BRAVO WITHOUT POWER STEERING
ALPHA WITH CLOSED COOLING
WITHOUT POWER STEERING
BRAVO WITH CLOSED COOLING
AND POWER STEERING
ALPHA WITH CLOSED COOLING AND
POWER STEERING
Index
90-823226--1 996
POWER STEERING - 8A-3
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INSTALLATION
Important Service
Information
Install pulley, as follows, using pulley installer tool
(91-93656A1), and a long straight edge:
1. Place pulley on pump shaft.
Pump Pulley Replacement
2. Thread stud all the way into pump shaft. Place
bearing over stud. Do not use spacer from kit.
REMOVAL
3. Thread nut onto shaft. Thread tool shaft (and nut)
all the way onto stud (threaded into pump pulley).
IMPORTANT: Kent-Moore Tool J-25034 must be
used to remove the pressed-on pulleys used on
power steering pumps. This tool has an end on it
that willnotmushroomtheendofthepumpshaft.
DO NOT use Kent-Moore Tool J-21239 to remove
these pulleys. Thistoolhasataperedendandwill
damage the shaft.
4. Using a long straight edge (to check drive belt
alignment), turn large pusher nut until drive belt
is parallel to straight edge.
5. Check pulley installation for correct alignment.
d
c
e
f
b
1. Install Kent-Moore Tool J-25034 on end of pulley
and shaft as shown.
2. While holding tool with suitable wrench, turn
threaded screw until pulley is removed.
a
i
72822
g
h
a - Power Steering Pump Pulley
b - Stud
c - Do Not Use Spacer
d - Bearing
72821
e - Nut
f - Tool Shaft
g - Crankshaft Pulley (shown) Or Water Circulating Pump
Pulley
a - Kent-Moore Pulley Removal Tool (J-25034)
h - Long Straight Edge
i - Drive Belt Parallel
Index
8A-4 - POWER STEERING PUMP
90-823226--1 996
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Serpentine Belt Adjustment
Testing and Repair
Refer to appropriate MerCruiser Stern Drive
Service Manual.
1. Usinga5/8inchwrench, loosenthenutonthead-
justment stud.
2. Place the 5/16 inch deep socket on the hex end
of the adjustment stud rotate starboard tensioner
until there is 1/4 inch (6 mm) deflection is
achieved between the pulleys with the greatest
distance between them (this location may be dif-
ferent with various belt configurations).
Checking Pump Fluid Level
Refer to Section 1B - “Maintenance” (see “Table of
Contents”).
3. While holding adjustment stud at the correct belt
tension, tighten locking nut.
Filling and Air Bleeding
System
Refer to Section 1B - “Maintenance” (see “Table of
Contents”).
b
Belt Adjustment
V-Belt
a
IMPORTANT: Do not pry on power steering pump
with pry bar or screwdriver. Serious damage may
result.
1. Install drive belt on pulleys and adjust tension as
follows:
a. Pivot pump away from engine, as required,
until correct tension is obtained, as shown.
b. After obtaining correct tension, securely
tighten pump brace and pump mounting
bolts.
2. If a new drive belt has been installed, recheck belt
tension after running for five minutes.
Bravo Model With Power Steering Shown (Other
Configurations Will Be Different)
a - Locking Nut
b - Adjustment Stud
a - Belt Should Depress 1/4 In (6 mm)
b - Screws and Nuts
Index
90-823226--1 996
POWER STEERING - 8A-5
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2. Install mounting hardware and fasteners to retain
pump to bracket. (Refer to “Exploded View” for
specific details on your engine.)
Pump Assembly
IMPORTANT: Be careful to not cross-thread or
over-tighten hose fittings.
1. Be certain a new high pressure hose O-ring is
present, and install threaded fitting in back of
pump assembly. Tighten fitting securely. Connect
low pressure hose on back of pump. Tighten
hose clamp securely.
a
72849
b
a
c
d
a
a - Pump
b - Bracket
b
c
c - Threaded Fitting
d - Low Pressure Hose
72848
a - Screw With :Lockwasher
b - Nuts (With Hardware)
c - Spacers
3. Install drive belt and adjust tension. Refer to
“Pump Drive Belt Adjustment” as previously out-
lined.
4. Fill and air bleed system. Refer to Section 1B -
“Maintenance” (see “Table of Contents”).
Index
8A-6 - POWER STEERING PUMP
90-823226--1 996
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2. Remove hose where routed and secured (port or
starboard side), across top of engine, near valve
cover.
Mounting Bracket
Mounting bracket is removable after pump (refer to
previous instructions) and alternator (refer to Section
4C - “Charging System”) have been removed. See
“Exploded View” and “Torque Specifications.”
3. Remove small fitting from control valve at tran-
som. Remove hose.
Hydraulic Hoses and Fluid
Cooler
Refer to Section 6A - “Seawater Cooled Models” or
Section 6B - “Closed Cooled Models” for information
on testing or servicing power steering fluid coolers.
The following is provided to assist in replacement of
power steering fluid hoses and to assure proper rout-
ing and connection to the cooler.
a
b
Replace high or low pressure hoses following:
0912
a - Control Valve
b - Small Fitting And Hose
IMPORTANT: Make hydraulic connections as
quickly as possible to prevent fluid leakage.
INSTALLATION
IMPORTANT: Be careful to not cross-thread or
over-tighten hose fittings.
!
CAUTION
Route hoses exactly as shown below. This will
help avoid stress on the hose fittings and will
help avoid kinks in the hoses.
High Pressure Hose
(Pump-to-Control Valve)
IMPORTANT: Be careful to not cross-thread or
over-tighten hose fittings.
REMOVAL
NOTE: Catch fluid that drains from pump and hoses
in a suitable container.
1. Thread small fitting into control valve. Position
hose properly (as prior to removal).
Earlier Style Control Valve: Torque small fitting to
96-108 lb. in. (11-12 N·m).
1. Remove high pressure hose fitting and O-ring
seal from rear of pump.
a
a
b
72848
a - Small Fitting
a - High Pressure Hose
b - Fitting (With O-Ring - Not Visible In This View)
Index
90-823226--1 996
POWER STEERING - 8A-7
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Later Style Control Valve: Torque fittings to 23 lb. ft.
(31 N·m)
Low Pressure Hose (Cooler-to-Pump)
REMOVAL
NOTE: Catch fluid that drains from hose, cooler
and pump in a suitable container.
1. Loosen hose clamp and remove hose from fluid
cooler.
c
b
73786
2. Route hose along valve cover and secure with
J-clamp(s) provided.
3. Be certain a new high pressure hose O-ring is
present, and install threaded fitting in back of
pump assembly. Tighten fitting securely. Do not
cross-thread or over-tighten.
72588
a
Port Side Mounted Fluid Cooler
a - Fluid Cooler
b - Hose Clamp
c - Hose
b
a
72848
a - Fitting (With O-Ring - Not Visible In This View)
a
4. Fill and air bleed system. Refer to Section 1B -
“Maintenance” (see “Table of Contents”).
74752
Rear Mounted Fluid Cooler
a - Fluid Cooler
b - Hose
Index
8A-8 - POWER STEERING PUMP
90-823226--1 996
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2. Loosen hose clamp and remove hose from back
of pump.
2. Using hose clamp, install hose on fluid cooler.
Ti
c
b
a
72588
a
b
Port Side Mounted Fluid Cooler
72848
a - Fluid Cooler
b - Hose Clamp
c - Hose
a - Hose Clamp
b - Hose
INSTALLATION
1. Using hose clamp, install new hose on back of
pump. Tighten clamp securely.
b
a
74752
Rear Mounted Fluid Cooler
a - Fluid Cooler
b - Hose
a
3. Fill and air bleed system. Refer to Section 1B -
“Maintenance” (see “Table of Contents”).
b
72848
a - Hose Clamp
b - Hose
Index
90-823226--1 996
POWER STEERING - 8A-9
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Low Pressure Hose
(Control Valve-to-Cooler)
REMOVAL
NOTE: Catch fluid that drains from hose, cooler
and pump in a suitable container.
1. Loosen hose clamp and remove hose from fluid
cooler.
a
72853
c
Port Side Mounted Fluid Cooler Only
a - J-Clamps
3. Remove large fitting from control valve at tran-
som. Remove hose.
b
a
a
72588
Port Side Mounted Fluid Cooler
a - Fluid Cooler
b - Hose Clamp
c - Hose
b
Earlier Style Control Valve
a - Large Fitting
a
a
74752
Rear Mounted Fluid Cooler
a - Fluid Cooler
b - Hose
73786
2. Remove hose where routed and secured across
top of engine flywheel housing.
Later Style Control Valve
a - Rear Fitting
Index
8A-10 - POWER STEERING PUMP
90-823226--1 996
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INSTALLATION
3. Using hose clamp, install hose on fluid cooler.
Tighten clamp securely.
!
CAUTION
Route hoses exactly as shown below. This will
help avoid stress on the hose fittings and will
help avoid kinks in the hoses.
c
IMPORTANT: Be careful to not cross-thread or
over-tighten hose fittings.
1. Thread large fitting into control valve. Position
hose properly (as prior to removal).
Earlier Style Control Valve: Torque large fitting to
20-25 lb. ft. (27-34 N·m).
b
a
a
72588
Port Side Mounted Fluid Cooler
a - Fluid Cooler
b - Hose Clamp
c - Hose
b
a - Large Fitting
Later Style Control Valve: Torque fittings to 23 lb. ft.
(31 N·m)
a
74752
Rear Mounted Fluid Cooler
a - Fluid Cooler
b - Hose
4. Fill and air bleed system. Refer to Section 1B -
“Maintenance” (see “Table of Contents”).
73786
2. Route hose along flywheel housing and secure
with J-clamp(s) provided.
Index
90-823226--1 996
POWER STEERING - 8A-11
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b. Install reservoir mounting bracket with hard-
ware supplied.
Priority Valve Kit (79691A1)
Information
This kit information (in “Installation Instruction” form)
is provided to assist personnel when servicing dual
installations where both engines are equipped with
power steering pumps, coolers, related hardware
and hoses, and one transom assembly is equipped
with power steering.
a
Although the system may already be installed, refer
to appropriate sections and follow instructions that
relatetoyourtaskwhenservicingthosecomponents.
NOTE: A system flow diagram is located on the
last page of this section.
1402
a - measurement - 6 Inch (152 mm) Minimum
Installing Reservoir
2. Position bottle reservoir in mounting bracket and
secure with retainer spring.
1. Mount reservoir bracket.
a. Find a location between both power steering
pumps that affords both accessibility and
easy visual inspection of fluid level. Location
must be at least 6 in. (152 mm) higher than
pump cap to allow fluid from reservoir to flow
freely to pumps (preferably on transom or on
forward engine compartment wall).
a
b
c
e
d
854
a - Reservoir Bracket
b - Reservoir Spring Retainer Tab
c - Screw and Washer (Not Shown In This View)
d - Reservoir Bottle
e - Retainer Spring
Index
8A-12 - POWER STEERING PUMP
90-823226--1 996
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IMPORTANT: A two-way valve is required on the
reservoir cap for cold weather operation below
40°F (4°C).
6. Secure hoses with Sta-Straps to keep them be-
low reservoir fluid level line and away from heat
and moving parts.
3. If required, install two-way valve in reservoir cap
by removing vent from cover and replacing it with
a two-way check valve.
b
c
b
d
a
e
a
72855
57
a - Reservoir Cap
b - Vent
a - Power Steering Pump Cap (Port and Starboard)
b - Hose To Reservoir
c - Hose Clamp
d - Sta-Straps
b
a
e - Bend Radius (Port and Starboard)
72856
a - Reservoir Cap
b - Two-Way Valve (Installed)
a
4. Cut two hoses (from bulk hose supplied) of suffi-
cient length to extend from bottom fittings on res-
ervoir to fill caps on power steering pumps. Allow
extra hose for routing.
b
IMPORTANT: When routing and installing hoses
in the following steps, be sure that the bend ra-
dius in the hose is sufficient to eliminate a load
being placed on power steering pump fill cap.
c
b
72858
5. Connect hoses, that were just cut, to reservoir
and power steering pump caps (from kit). Secure
with hose clamps. Tighten securely.
a - Reservoir
b - Hoses From Pumps
c - Hose Clamps
Index
90-823226--1 996
POWER STEERING - 8A-13
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NOTE: The 90° elbow locations on priority valve
Installing Priority Valve
are marked with a “T” stamped into the valve.
NOTE: Priority valve mounting bracket can be
used in various mounting configurations.
2. Apply liquid pipe joint sealer to threads and install
fittings into priority valve.
b
a
c
c
a
71404
a - 90 Degree Elbow
b - Large Inverted Flare Fitting
c - Small Inverted Flare Fitting
1. Install priority valve mounting bracket.
a. Find a central location that will be accessible
for making and checking hose connections.
Ensure that location will allow 2 in. (51 mm)
or more, above and below priority valve for
hose connections and routing (preferably on
a stringer near transom).
3. Mount priority valve on bracket. Torque bolt to
120 lb. in. (14 N·m).
b
b. Mount bracket using lag bolts and washers
supplied.
a
a
d
c
b
72860
a - Bolt and Washers
b - Washer and Nut (Not Shown In This View)
c - Bracket
b
d - Priority Valve
72859
a - Mounting Bracket
b - Lag Bolts and Washers
Index
8A-14 - POWER STEERING PUMP
90-823226--1 996
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NOTE: Engines with power steering are
equipped with a hose that is connected to the
power steering fluid cooler. A fitting on the other
end of the hose would normally be connected to
the power steering control valve. These hoses
are not used and are replaced with bulk hose
supplied with priority valve kit.
from kit) to power steering control valve. Route
hose to priority valve, cut hose to length, and con-
nect to fitting on priority valve. Secure with hose
clamp. Tighten securely.
4. Remove and discard old (control valve-to-cooler)
hoses which are connected to power steering
cooler (port and starboard).
a
5. Cut two hoses (from bulk hose supplied) of suffi-
cient length to extend from power steering cool-
ers to respective fittings on priority valve.
6. Connect one end of each hose to its respective
power steering fluid cooler and other ends to fit-
tings on priority valve. Secure with hose clamps.
Tighten securely.
b
b
863
c
c
a
72588
a - Power Steering Fluid Cooler
b - Hose
b
c - Hose Clamp
a
b
c
a
4
72862
c
a - Priority Valve
b - Hose
c - Hose Clamp
b
a - Priority Valve
b - Hose
c - Hose Clamp
7. Install return hose (large fitting on one end only,
Index
90-823226--1 996
POWER STEERING - 8A-15
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8. Install pressure hose (fittings on both ends, from
kit) between power steering control valve and
large inverted flare fitting on priority valve. (This
fitting location is marked with an “S.”) Secure with
hose clamp. Tighten securely.
9. Connect No. 1 (starboard) engine pressure hose
(from pump) to inverted flare fitting marked by “1”
on priority valve. Connect No. 2 (port) pressure
hose (from pump) to inverted flare fitting marked
by “2” on priority valve. Secure with hose clamps.
Tighten securely.
a
b
a - Power Steering Control Valve
b - Hose Fitting
c
72867
b
a - Priority Valve
b - No. 1 (Starboard) Pressure Hose
c - No. 2 (Port) Pressure Hose
10. Secure all hoses with Sta-Straps provided.
a
66
a - Priority Valve
b - Hose Fitting
Index
8A-16 - POWER STEERING PUMP
90-823226--1 996
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Filling System with Fluid
Maintenance
1. Fill pump reservoirs with automatic transmission
fluid (ATF) Dexron ll or Dexron lll.
Maintenance inspection is the owner’s responsibility
and must be performed at the following intervals:
2. Install and tighten pump cap by turning cap clock-
wise approximately 120 degrees.
Normal Service - Every 50 hrs. of operation or
60 days (whichever comes
first)
Severe Service - Every 25 hrs. of operation or
30 days (whichever comes
first)
a
NOTE: Operation in salt water is considered se-
vere service.
1. Check all connections and hose clamps for ade-
quate tightness. Tighten, if loose.
2. Checkallmountingboltsandtightenifnecessary.
3. Be sure to check reservoir oil level periodically.
a - Cap
3. Fill reservoir bottle to full mark, then (one at a
time) slightly loosen pump cap to allow fluid to
flow from reservoir to pump until pump just starts
to overflow, then quickly tighten pump cap. Fill
bottle reservoir and repeat this process for the
other pump.
4. Double check both caps to ensure they are both
tight.
Index
90-823226--1 996
POWER STEERING - 8A-17
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System Flow Diagram
1
1 - Reservoir Bottle and Bracket
2 - Priority Valve and Mounting Bracket
3 - Power Steering Control Valve
4 - Power Steering Pump
5 - Power Steering Fluid Cooler
a - Pressure Hose (Fitting On Both Ends - Supplied In Kit)
b - Return Hose (Fitting On One End - Supplied In Kit)
c - Return Hose From Pump (Cut From Bulk Hose Supplied)
d - Pressure Hose From Pump
e - Return Hose From Pump
f - Gravity Feed Hose (Cut From Bulk Hose Supplied)
Index
8A-18 - POWER STEERING PUMP
90-823226--1 996
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THIS PAGE IS INTENTIONALLY BLANK TO
ALLOW FOR CORRECTIONS OR ADDITIONS
AT A LATER DATE
Index
90-823226--1 996
POWER STEERING - 8A-19
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