3803224 Volvo.Penta Aquamatic drive, exc

Table 1
Required Tools
Tool Part Number Part Description Qty
A 439-3938 Link Bracket 1
B - 5/8 in x 11 NC x 4 in Guide Bolts 2
C - Loctite 243 Threadlocker 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Install the Pump
Illustration 1 g01057277
Lubricate the bore for O-ring seal (5) with clean engine oil. Install the O-ring seal onto the mounting flange of the auxiliary water pump.
Illustration 2 g01057279
Install Tooling (B) into the upper bolt holes for the auxiliary water pump on the front housing.
Illustration 3 g01057284
Attach Tooling (A) and a suitable lifting device to auxiliary water pump (4). The weight of the auxiliary water pump is approximately 64 kg (140 lb). Use a suitable lifting device to lift the auxiliary water pump onto Tooling (B). Carefully move the auxiliary water pump toward the front housing.If the shaft of the auxiliary water pump does not fit into the drive gear, move the auxiliary water pump slightly away from the front housing. Rotate the shaft slightly until the splines of the shaft will fit properly into the drive gear.
Illustration 4 g01055719
Continue to support the auxiliary water pump. After the shaft of the auxiliary water pump is fully engaged in the drive gear, install two bolts (3) and the washers into the lower bolt holes for the auxiliary water pump on the front housing. Remove Tooling (B) from the front housing. Install the other two bolts (3) and the washers. Remove Tooling (A) from the auxiliary water pump.Install the Check Valve
Install the studs for the check valve into the holes around the outlet of the auxiliary water pump.
Inspect the gasket for the joint between the check valve and the auxiliary water pump. If the gasket is damaged and/or deteriorated, obtain a new gasket. Install the gasket onto the outlet of the auxiliary water pump.
Illustration 5 g00715046
Place the body of check valve (2) onto the studs at the outlet of the auxiliary water pump.
Ensure that the threads of hose assembly (1) are thoroughly clean. Coat the threads of the hose assembly with Tooling (C). Attach the hose assembly to the check valve and the auxiliary water pump.Note: After the auxiliary water pump has been drained, the auxiliary water pump must be filled with water before use.
Inspect the gasket for the joint between the check valve and the water line. If the gasket is damaged and/or deteriorated, obtain a new gasket. Install the gasket onto the outlet of the check valve.
Install the water line to the outlet of the check valve. Use nuts and washers to attach the flange of the water line to the check valve. Tighten the nuts to a torque of 29 4 N m (21 3 lb ft).
Inspect the gasket for the joint between the water line and the inlet of the auxiliary water pump. If the gasket is damaged and/or deteriorated, obtain a new gasket. Install the gasket onto the inlet of the auxiliary water pump.
Install the water line to the inlet of the auxiliary water pump. Use bolts and washers to attach the flange of the water line to the auxiliary water pump. Tighten the bolts to a torque of 29 4 N m (21 3 lb ft).