21252233 Volvo.Penta Piston ring kit

1. Release the pressure in the cooling system by slowly loosening the filler cap on the radiator. Drain the coolant from the radiator. Identify and mark all hoses and electrical wiring for purposes of reassembly.2. Remove the support clips and disconnect wires (1).3. Disconnect heater hose (3) from elbow (2).4. Loosen the hose clamp holding hose (4) to elbow (2).5. Remove the two bolts holding elbow (2) to the cylinder head assembly. 6. Loosen two hose clamps (8). Remove hose (7) from the water pump.7. Remove two bolts (5), water pump (6) and elbow (2) as a unit from the engine and hose (4). Replace the gasket located beneath elbow (2) with a new one.8. Check the condition of the O-ring seal located between the water pump housing and the engine. If the seal is worn or damaged, replace it with a new one. Use 1U6395 O-Ring Compound when installing the O-ring seal. 9. Remove two bolts (9) and elbow (2) from water pump (6). Replace the gasket located between the water pump and elbow (2). The following steps are for installing the water pump.10. Position the gasket and elbow (2) on water pump (6). Install and tighten bolts (9).11. Position water pump (6) into hose (4) and onto the engine. Make sure the O-ring seal beneath the water pump and the gasket beneath elbow (2) stay in place.12. Install the water pump in the reverse order of removal.13. Fill the cooling system with coolant to the correct level. See the Operation & Maintenance for the correct filling procedure.Disassemble Water Pump
Start By:a. remove water pump 1. Remove bolt (1) and the washer. Remove bearing (2) and gear (3) as a unit.2. Use tooling (A), (C) and a press, and remove bearing (2) from gear (3). 3. Remove snap ring (4) with tool (B). 4. Remove bolts (5), the washers and cover (6) from the water pump. 5. Loosen bolt approximately 6.4 mm (.25 in). Hit the bolt with a soft hammer to remove impeller (8) from the shaft.6. Remove the spring and seal assembly from the shaft. 7. Remove bearing (9) and shaft (10) as a unit. 8. Use tooling (A) and tooling (C) in a press as shown to remove bearing (9) from shaft (10). 9. Remove the ceramic ring and seal (11) from the housing. 10. Use tool (C) to remove lip-type seal (12) from the housing.Assemble Water Pump
1. Use tool C to install the lip-type seal in the water pump housing. The lip of the seal must be toward the bearings. Put clean engine oil on the lip of the seal. 2. Install shaft (1) in bearing (2) with a press. 3. Install shaft (1) and bearing (2) in the housing as shown. 4. Install snap ring (3) with tool (B).
Clean water only is permitted for use as a lubricant for assembly. 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 (4) in position in the rubber seal. Use hand pressure and the tool (which is with the replacement ring) to install the ceramic ring. 6. Remove the spring from seal assembly (5). Use hand pressure and the tool (which is with the replacement ring) to install the seal assembly. Push seal assembly (5) on the shaft until it makes light contact with ceramic ring (4). 7. Install spring (6) as shown. Put impeller (7) in position on the shaft, and install the washer and bolt that hold it. Tighten the bolt to a torque of 38 1.5 N m (28 1 lb ft). 8. Put the gasket and cover (8) in position on the water pump housing, and install the washers and bolts (9) that hold them. 9. Install bearing (10) on gear (11) with a press.
Make sure pins (12) align with the holes in shaft (1) when installing gear (11).
10. Position gear (11) onto shaft (1). Pins (12) must be aligned with the holes in shaft (1).11. Install the washer and bolt that holds gear (11) to shaft (1). Tighten the bolt to 97 7 N m (72 5 lb ft).End By:a. install water pump