981735 Volvo.Penta Cap plug

2. Remove tube (1) from the water pump elbow to the exhaust manifold.3. Remove bolt (2) that holds the breather tube clip to the water pump. 4. Loosen hose clamp (3) and slide the clamp away from the water pump elbow.5. Disconnect the hose from the radiator at the water pump. 6. Remove bolts (4) that hold the water pump elbow to the cylinder head.7. Remove two bolts (5) and washers that hold water pump (6) to the front housing. Remove the water pump and elbow as a unit.Install Water Pump
1. Put a new water pump elbow gasket in place and install water pump (1). Install the bolts and washer that hold the water pump and elbow in place. 2. Put a thin layer of engine oil on seal (3).3. Put a new gasket between the exhaust manifold and tube (2) in position. Install tube (2) and bolts that hold the tube in place.4. Tighten the hose clamp on the hose to the oil cooler. 5. Install the bolt and washer that hold the breather tube clip (4) in place.6. Connect the hose from the radiator to the water pump.7. Fill the cooling system with coolant to the correct level.Disassemble Water Pump
start by:a) remove water pump 1. Remove cover (3) and gasket from water pump (1).2. Remove elbow (2) and gasket from water pump (1). 3. Loosen bolt (5) .25 in. (6.35 mm). Hit (tap) the bolt with a soft hammer to remove impeller (4) from the shaft. 4. Remove spring and seal assembly (7) from shaft (6). 5. Turn the water pump over and remove bolt (8) and lockwasher.6. Remove O-ring seal (9) from the housing. 7. Use tooling (A) to remove gear (11) and bearing (10) from the water pump.8. Remove bearing (10) from gear (11). 9. Remove snap ring (12) with tool (B). 10. Remove bearing (14) and shaft (13) as a unit. 11. Use tool (C) and a press to remove bearing (14) from the shaft. 12. Remove the ceramic ring and seal (15) from the housing. 13. Remove the lip type seal (16) from the housing with tooling (D).Assemble Water Pump
The seal must be installed with the lip toward the bearings. 1. Install the lip type seal in housing (1) with tooling (A) to the bottom of the seal counterbore. Put a thin layer of engine oil on the lip of the seal. 2. Use a press to install shaft (2) in bearing (3). 3. Install the shaft and bearing (3) in housing (1). 4. Install snap ring (4) in the housing with tool (B). 5. Install bearing (5) on gear (6).
When gear (6) is installed, make sure the pins on the gear engage the holes in the shaft.
6. Put gear (6) and bearing in position on the shaft and install washer and bolt. 7. Install O-ring seal (7) on the housing.
Clean water only is permitted for use as a lubricant to make assembly easier. Do not damage or put hands on the wear surface of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal assembly.
8. Put the ceramic ring (8) in position in the rubber seal. Use hand pressure and tool (which is with the replacement ring) to install the ceramic ring and rubber seal. 9. Remove the spring from the seal assembly (9). Use hand pressure and the tool (which is with the replacement ring) to install the seal assembly. Push seal assembly on the shaft until seal faces make light contact. 10. Install spring (10) on the seal assembly. 11. Put impeller (11) in position on the shaft. 12. Install washer and bolt (12). Tighten the bolt to a torque of 28 1 lb.ft. (39 1 N m).13. Install a new gasket and cover (13) on the housing. 14. Install a new gasket and elbow (14) on the housing.end by:a) install water pump