20798191 Volvo.Penta Cylinder head gasket, cylinder head

At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Drain the coolant only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap from the radiator slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to avoid personal injury.
Photos taken out of chassis. 1. Use Tooling (A) and carefully release the tension of spring (1) on V-belts (2) and remove V-belts (2). 2. Remove two bolts (4) at elbow (3). Remove bolts (5) and cover (6). 3. Remove four bolts (10) holding oil cooler bonnet (11) to the water pump.4. Disconnect coolant conditioner line (9).5. Remove four nuts and one bolt (7) and waster pump (8). Install in reverse order.6. Check O-ring seals on the front and rear face of the water pump and replace if worn or damaged.7. Install new gasket between oil cooler bonnet (11) and the water pump.8. Install new gasket on elbow (3).9. Fill the cooling system to the correct level. See the Operation and Maintenance Manual.Disassemble Water Pump
Start By:a. remove water pump 1. Remove O-ring seal (1) from adapter (2).2. Remove adapter (2) with a screwdriver. Remove the seal from the edge of adapter (2).3. Remove bolt (3) and the washer. 4. Remove impeller (4) from the water pump housing with Tooling (A). 5. Remove seal assembly (5). Remove ring and seal (6). 6. Remove the bolt and washer that hold gear (7) on the water pump shaft.7. Remove gear (7) with Tooling (B).8. Remove bolts and retainer (9).9. Remove O-ring seal (8). 10. Remove shaft (10) and the bearings as a unit.11. Remove bearing (11), spacer (12) and bearing (13) from shaft (10).12. Remove the lip-type seal from the gear side of the water pump. Remove the ring and seal from the impeller side of the water pump.13. Use 6V-1541 Quick Cure Primer to clean shaft (10) and the seal counterbore in the pump housing.Assemble Water Pump
1. Install seal (1) with Tooling (A) as shown. Put clean engine oil on the lip of the seal. 2. Install bearing (4), spacer (3) and bearing (5) on shaft (2). Install shaft (2) in the pump housing. 3. Install retainer (7) and O-ring seal (8).4. Install gear (6). Install washer and bolt that hold gear (6) to shaft (2).
Clean water only is permitted for use as a lubricant for assistance at installation. 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.
5. Put ceramic ring (10) in position in rubber seal (9). Use hand pressure and Tool (B) to install the ceramic ring and seal in the housing.
Avoid contaminating the seal faces with grease or oil. Also, avoid stretching the rubber seal during installation.
The carbon seal assembly must rotate with the water pump shaft after installation.6. Remove spring (12) from seal assembly (11). Use hand pressure and the Tool (which is with the replacement ring) to install the seal (11) assembly. Push seal assembly on the shaft until the seal face makes light contact.7. Install spring (12) on the shaft. 8. Install impeller (14) and the washer and bolt (13) that hold the impeller to the pump shaft. Tighten bolt (13) to a torque of 39 3 N m (28 2 lb ft) Make an air pressure test of the seal at 140 kPa (20 psi). 9. Put clean engine oil on the O-ring seals (15). Install the O-ring seals on adapter (16).10. Install adapter (16) in the pump housing with the notch in alignment with dowel (17).End By:a. install water pump