20572766 Volvo.Penta Flange

At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water or steam. Any contact can cause severe burns. Look at the sight gauge to check the coolant level. The coolant level should be in the green range. If necessary, remove the fill cap only after the engine has been stopped and the cap is cool enough to remove with your bare hand. Remove the cooling system fill cap slowly to relieve pressure. Cooling system condition contains alkali that can cause personal injury. Avoid contact with the skin and eyes and do not drink. Allow cooling system components to cool before draining.
Mark and identify all hose assemblies for installation purposes. Cap and plug all hose assemblies to avoid system contamination. 1. Position a suitable container under drain plug (2) to contain the coolant for storage or disposal. Loosen drain plug (2) on plug adapter (1). Repeat procedure on remaining drain plug. The capacity of the cooling system is 300 L (79 U.S. gal). 2. Loosen four hose clamps (3) on hose (4). Disconnect hose assembly (5) from elbow (6). 3. Mark and identify bolts (7) for installation purposes. Remove four bolts (7) that hold elbow (9) to auxiliary fresh water pump (10). Set hose assembly (8) out of the way. Remove elbow (9) from auxiliary fresh water pump (10). 4. Disconnect hose assembly (11) from elbow (12). 5. Remove four bolts (13) and the nuts that hold elbow (15) to auxiliary fresh water pump (10). Disconnect tube assembly (14) from auxiliary fresh water pump (10). 6. Remove O-ring seal (18) from auxiliary fresh water pump (10). Remove six bolts (17) from auxiliary fresh water pump (10). Remove auxiliary fresh water pump (10) and the O-ring seal from the accessory drive. The weight of auxiliary fresh water pump (10) is 21 Kg (47 lb).7. Remove gasket (16) from elbow (15). The following steps are for the installation of the auxiliary fresh water pump Inspect all O-ring seals for wear or damage and replace as necessary. Clean all mating surfaces of gaskets prior to installation. Lightly lubricate the O-ring seal and bore, located between the auxiliary fresh water pump and the accessory drive, with engine oil prior to assembly to avoid leakage. 8. Install O-ring seal (18) to auxiliary fresh water pump (10). Put gasket (16) in position on elbow (15).9. Put auxiliary fresh water pump (10) and the O-ring seal in position on the accessory drive. Install six bolts (17) to auxiliary fresh water pump (10). The weight of auxiliary fresh water pump (10) is 21 Kg (47 lb). 10. Install four bolts (13) and the nuts to auxiliary fresh water pump (10). Connect tube assembly (12) to auxiliary fresh water pump (10). 11. Connect hose assembly (11) on to elbow (12). 12. Put elbow (9) in position on auxiliary fresh water pump (10). Put hose assembly (8) in position and install four bolts (7) that hold elbow (9) to auxiliary fresh water pump (10) 13. Connect hose assembly (5) to elbow (6). Tighten four hose clamps (3) on hose (4). 14. Close drain plug (2) on plug adapter (1). Fill the engine cooling system. The capacity of the cooling system is 300 L (79 U.S. gal).Disassemble Auxiliary Fresh Water Pump
Start By:a. remove auxiliary fresh water pump 1. Remove O-ring seals (3) and (4) from the housing assembly.2. Remove the twelve bolts and gear (2) from pump drive shaft assembly (1). 3. Remove the four bolts and inlet adapter (5) from the housing assembly. Remove the O-ring seal from inlet adapter (5). 4. Loosen bolt (6) holding pump impeller (7) to the shaft assembly.5. Use Tooling (A) to loosen pump impeller (7) from the shaft assembly. Remove Tooling (A). Remove the washer, bolt (6), and pump impeller (7) from the shaft assembly and housing assembly. 6. Remove spring (9) from seal group (10). Remove seal group (10) from the end of shaft assembly (8). 7. Remove the four bolts that hold thrust washers (12) to the housing assembly. Remove pump drive shaft assembly (1) and thrust washers (12) from the housing assembly. 8. Remove the four bolts and four shim carriers that hold the two thrust washers (13) to the housing assembly. Remove shaft assembly (8) and thrust washers (13) from the housing assembly.9. Remove the rubber ring and ceramic seal (11) from the housing assembly. 10. Remove lip seal (14) from the housing assembly. 11. Remove sleeve bearing (15) from the housing assembly.Assemble Auxiliary Fresh Water Pump
When installing sleeve bearing (15) make sure the lubrication hole in the sleeve bearing is aligned with the oil passage in the housing assembly. Failure to do so could result in pump failure.
1. Position sleeve bearing (15) on the housing assembly making sure the oil passages are in alignment. Use Tooling (A) and a press to push sleeve bearing (15) in the housing assembly. Sleeve bearing (15) should be 1.5 0.5 mm (.06 .02 in.) below the surface of the housing assembly. 2. Position lip seal (14) in the housing assembly. Make sure the lip of seal (14) faces toward sleeve bearing (15) as shown. Install lip seal (14) with a press and Tooling (A). Lubricate lip seal (14) with the fluid being sealed. 3. Install shaft assembly (8) in the housing assembly. Install the thrust washers (13), shim carriers and bolts in the housing assembly. 4. Install pump drive shaft assembly (1) and thrust washers (12). Install the bolts that hold thrust washers (12) on the housing assembly.
Use clean water as the only lubricant when installing the seal group in the housing assembly. Use care when handling the seal group during installation. 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 (11) in position in the rubber ring. Lubricate ceramic ring (11) and rubber