1994 Johnson/Evinrude "ER" 2 thru 8 outboards Service Manual, Page 227Get this manual
28If you have disassembled the impeller housing components, reassemble them at this timeOil the tips of the impellerScrew impeller into the cup in counterclockwise directionLightly coat the exterior of the impeller cup with OMC Gasket Sealing CompoundInstall the cup and impellerSlide the water pump assembly down over the driveshaft and position itApply OMC Gasket Sealing Compound to threads of the four impeller housing screwsInstall and tighten the four screws to torque of 60-84 inIbs(7-9 Nm)4 2129Pressure and vacuum test the gearcase as follows: INotel Pressure and vacuum test gearcase before filling Remove the oil level plug and screw in pressure test gauge Pump pressure up to 3-6 PSI (21-42 kPa)If pressure gauge indicates leakage, submerge the gearcase in water to determine source of leakage as evidenced by bubblesIf the gearcase pressure gauge does not indicate leakage, increase pressure to 16-18 PSI (110-124 kPa)If pressure does not hold, submerge the gearcase in water and check for source of leakageMake necessary repairs and repeat test Screw in vacuum testerPump out to 3-5 in(76-127 mm) of mercury and see if vacuum holdsThen pump out to 15 in(381 mm) of mercury and checkIf the gearcase fails to hold on either test, put oil around suspected sealIf leak then stops or oil is drawn in, that seal is defectiveReplace defective components, test, and fill gearcase1431 30Fill the gearcase with 10-11 flo oz(290-325 ml) lubricant as follows: Secure the gearcase in an upright position Remove the oil level and the oil filldrain plugsReplace the seals if damaged Fill the gearcase with OMC Ultra-HPFgearcase lube until lubricant appears at the oil level holeInsert the oil level plug firstInvert the gearcase and remove the oil fill hoseInstall the filldrain plugTighten the oil level and the filldrain plugs to torque of 84-86 inIbs(9-10 Nm) Inspect the gearcase oil level after motor test has been performed 1