21393207 Volvo.Penta Idler pulley

1. Drain the coolant from the cooling system, and disconnect the inlet and outlet lines from pump (2).2. Remove cover (1) and the O-ring seal from the pump drive adapter. 3. Remove the bolts and adapter (3) from the front drive housing. 4. Remove O-ring seal (5) from adapter (3).5. If necessary, remove bearing (4) from adapter (3). 6. Fasten a hoist to pump (2) with tooling (A) as shown. Remove the bolts that hold pump (2) in position. Pull the pump and drive gear out of the front housing, and remove the unit from the engine. The weight of the unit is 39 kg (86 lb.).Install Auxiliary Pump (Fresh Water)
1. Install O-ring seal (1) around the pump body, and put clean engine oil on it.2. Use tool (A) to fasten a hoist to the pump, and put it in position in the front drive housing. Install the bolts and washers to hold the pump. 3. Make sure the oil hole in the bearing is in alignment with the oil passage in adapter (2). Use tool group (B) and a press to push the bearing into adapter (2) until it is 1.5 0.5 mm (.06 .02 in.) below the surface of adapter (2). The inside diameter of the bearing must be 75.000 0.055 mm (2.9528 .0022 in.) after assembly. 4. Install O-ring seal (3) around adapter (2), and put clean engine oil on it. Install adapter (2) in the front drive housing. 5. Install O-ring seal (4) around cover (5), and put clean engine oil on it. Install cover (5) on the adapter.6. Connect the inlet and outlet lines to the water pump, and fill the cooling system with coolant to the correct level. See the Maintenance Manual.Disassemble Auxiliary Pump (Fresh Water)
Start By:a. remove auxiliary pump (fresh water) 1. Remove O-ring seals (3) and (4) from the pump housing.2. Remove the bolts and gear (2) from shaft (1). 3. Remove the bolts and adapter (5) from the pump housing. Remove the O-ring seal from adapter (5). 4. Loosen bolt (6) and the washer that hold impeller (7) to the shaft.5. Use tooling (A) to loosen impeller (7) from the end of the pump shaft. Remove tooling (A), bolt (6), the washer and impeller (7) from the pump shaft and housing. 6. Remove spring (9) from carbon seal assembly (10). Remove carbon seal assembly (10) from the end of shaft (8). 7. Remove the bolts that hold retainer washers (12) to the pump housing. Remove shaft (1) and washers (12) from the pump housing. 8. Remove the bolts that hold the shims and retainer washers (13) to the pump housing. Remove shaft (8), the shims and washers (13) from the pump housing.9. Remove the rubber ring and ceramic seal (11) from the pump housing. See illustration B24522X1. 10. Remove lip-type seal (14) from the pump housing. 11. Remove bearing (15) from the pump housing.Assemble Auxiliary Pump (Fresh Water)
1. Make sure the oil hole in the bearing is in alignment with the oil passage in housing (1). Use tool group (A) and a press to push the bearing in housing (1) until it is 1.5 0.5 mm (.06 .02 in.) below the surface of housing (1). The inside diameter of the bearing must be 75.000 0.055 mm (2.9528 .0022 in.). 2. Use tool group (A) to install the lip-type seal in housing (1). Make sure the lip of the seal is toward the bearing as shown. Put clean engine oil on the lip of the seal. 3. Install shaft (2) in the pump housing. Install retainer washers (3), the shims and bolts to hold shaft (2) in the pump housing. 4. Put clean engine oil on the bearing in the pump housing, and install shaft (4) and retainer washers (5) over shaft (2). Install the bolts to hold retainer washers (5) to the pump housing.
Clean water only is permitted for use as a lubricant for assembly. Do not damage or put hands on the wear surfaces 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. Install ceramic seal ring (6) in the rubber seal. Put clean water on the rubber seal and ceramic seal ring for lubrication. Use hand pressure and the tool (which is with the replacement seal group) to install the seal and seal ring as shown. 6. Remove the spring from carbon seal assembly (7). Put clean water on the inside diameter of the seal assembly for lubrication. Use hand pressure and the tool (which is with the replacement seal group) to push seal assembly (7) on the shaft until seal faces make light contact. 7. Install spring (8) on carbon seal assembly (7). 8. Put impeller (9) in position on the pump shaft as shown. 9. Install the bolt and washer that hold impeller (9) to the pump shaft. Tighten the bolt to a torque of 38 4 N m (28 3 lb.ft.). 10. Install O-ring seal (11) around adapter (10), and put a small amount of engine oil or glyceride on it.11. Put adapter (10) in position, and install the bolts to hold it to the pump housing. 12. Put gear (12) in position on shaft (4), and install the bolts to hold gear (12). 13. Install O-ring seals (13) and (14) in the pump housing, and put clean engine oil on the O-ring seals.End By:a. install auxiliary pump (fresh water)