20838068 Volvo.Penta Crankshaft

1. Drain the coolant from the cooling system.
Typical Example. Bolts (6) can not be seen from this angle.2. Loosen the clamp and remove hose (4) from elbow (2).3. Remove the bolts and retainers that hold tube (1) to elbow (2).4. Disconnect any remaining hoses and sensors from elbow (2).5. Remove bolts (3) and elbow (2) from water pump housing (5). Check the condition of the O-ring seal beneath elbow (2). If the O-ring seal appears worn or damaged, use a new part for replacement.6. Fasten a hoist to water pump housing (5).7. Remove bolts (6) from the back side of water pump housing (5) and the front drive housing. Remove the water pump assembly. The weight of the water pump is assembly is 29 kg (64 lb).8. Check the condition of the O-ring seal located between water pump housing (5) and the front drive housing. If the O-ring seal appears worn or damaged, use a new part for replacement. The following steps are for installation of the water pump. Check the condition of all O-ring seals and components. If any seals or components are worn or damaged use new parts for replacement.9. Put clean engine oil on the O-ring seal that fits between water pump housing (5) and the front drive housing. Install the O-ring seal onto water pump housing (5).10. Fasten a hoist to water pump housing (5). Put the water pump assembly in position and install bolts (6) through the back of the front drive housing and into water pump housing (5).11. Put clean engine oil on the O-ring seal for tube (1).12. Put clean engine oil on the seal for elbow (2). Install the O-ring seal onto elbow (2).13. Put elbow (2) in position onto tube (1) and water pump housing (5). Install bolts (3).14. Install the retainers and bolts that hold tube (1) in position in elbow (2).15. Put hose (4) in position on elbow (4), and tighten the clamps that hold it in place.16. Connect the remaining hoses and sensors in their original positions to elbow (2).17. Fill the cooling system with coolant to the correct level. See the Operation & Maintenance module for further information.Disassemble Water Pump
Start By:a. remove water pump 1. Remove O-ring seal (4) from the back of housing assembly (3).2. Remove washer (1) that holds shaft assembly (2) in housing assembly (3).
Typical Example3. Remove cover (5) from housing assembly (3). Remove the O-ring seal from cover (5).
Typical Example4. Loosen bolt (7) holding impeller (6) to the pump shaft. Use tooling (A) to loosen impeller (6) from the end of the pump shaft. Remove tooling (A), bolt (7), the washer and impeller (6) from the pump shaft and housing assembly (3).
Typical Example5. Remove spring (9) from seal assembly (8) and shaft assembly (2).6. Use a soft hammer, and push shaft assembly (2) out of seal assembly (8) and housing assembly (3). Remove seal assembly (8) from housing assembly (3). 7. Remove ceramic seal (10) from the rubber ring. Remove the rubber ring from housing assembly (3). 8. Remove seal (11) from the back of housing assembly (3).Assemble Water Pump
1. If necessary, make a replacement of the two filters in the pump housing at location (12).2. If necessary, make a replacement of plug (13) and the seal beneath plug (13).3. Use tooling (A) to install seal (11) into housing (3). Make sure the lip of the seal faces toward the outside as shown. Lubricate the lip seal (11) with clean engine oil. 4. Install shaft assembly (2) into housing (3). Install thrust washer (1) and the bolts to hold shaft assembly (2) in position.
Use clean water as the only lubricant when installing seal group (8). Use care when handling seal group (8) during installation onto pump shaft (2). Touching the wear surfaces of the carbon or ceramic rings can cause contamination or damage. Install the smoothest face of the ceramic ring toward the carbon seal assembly.
5. Put ceramic seal (10) in position in the rubber ring. Use hand pressure and tool (B) to install the ceramic seal.
Typical Example6. Remove the spring from seal assembly (8). Use hand pressure and tool (B) to install the seal assembly. Push the seal assembly on the shaft until the seal faces make light contact.
Typical Example7. Install spring (9) on the carbon seal assembly.8. Put impeller (6) in position on the pump shaft as shown.
Typical Example9. Install the washer and bolt (7). Tighten bolt (7) to a torque of 200 25 N m (150 18 lb. ft.). 10. Make sure the studs for cover (5) are tightened in the pump housing. Torque the three studs to 45 7 N m (33 5 lb ft).11. Install the O-ring seal on cover (5). Lubricate the O-ring seal with clean engine oil. Position cover (5) onto the pump housing. Install and evenly tighten the nuts for cover (5). Torque the nuts holding cover (5) to 27 4 N m (20 3 lb. ft.).End By:a. install water pump