192134 Volvo.Penta Plug

At operating temperature, the engine cooling system is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap on the radiator is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with shin and eyes to prevent personal injury.
1. Disconnect two wires (1). Loosen clamp (3) holding the hose to housing (4).2. Remove two upper bolts (2).3. Remove two bolts (5) marked with an "X".4. Remove water pump (6) and housing (4) as a unit. 5. Remove two bolts (8) and housing (4) from water pump (6).6. Remove O-ring seal (10).7. Replace gasket (7) and (9) if necessary. Removal of the water pump in the machine also requires loosening the hose clamp holding the bottom radiator hose to the water pump. The following steps should be followed for the installation of the water pump.8. Install water pump first and then install gaskets and housing to the water pump. The gear on the water pump and the drive gear will be easier to line up without the housing on the pump. See "Lubricant Viscosities & Refill Capacities" in the Operation & Maintenance Manual.9. Fill the cooling system with coolant to the appropriate level.Disassemble & Assemble Water Pump
The following tools are needed for disassembly. Start By:a. remove water pump 1. Remove bolt (15) and the washer. Remove bearing (12) and gear (10) as a unit.2. Use tooling (A), (C) and a press, and remove bearing (12) from gear (10).3. Remove snap ring (8) with tool (B).4. Remove two bolts (1). The washers, cover (14) and gasket (2) from water pump housing (18).5. Loosen bolt (13) approximately 6.4 mm (.25 in). Hit the bolt with a soft hammer to loosen impeller (16) from shaft (9).6. Remove bolt (13), washer (11), impeller (16), spring (3) and seal assembly (4) from shaft (9).7. Remove bearing (7) and shaft (9) as a unit.8. Use tooling (A), (C) and a press to remove bearing (7) from shaft (9).9. Remove ceramic seal (5) and seal (17) from water pump housing (18).10. Use tool (C) to remove lip-type seal (6) from the water pump housing. The following steps are for assembly of the water pump. The following tools are needed for assembly. 11. Install lip-type seal (6) in water pump housing (18) with tool (C). The lip of the seal must be toward the bearings. Put clean engine oil on the lip of the seal.12. Install shaft (9) in bearing (7) with a press.13. Install shaft (9) and bearing (7) as a unit in water pump housing (18).14. Install snap ring (8) 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.
15. Put ceramic ring (5) in position in seal (17). Use hand pressure and tool (D) to install the ceramic ring.16. Remove spring (3) from seal assembly (4). Use hand pressure and tool (D) to install the seal assembly. Push seal assembly (4) on shaft (9) until it makes light contact with ceramic ring (5).17. Install spring (3) on seal assembly (4). Put impeller (16) in position on shaft (9), and install washer (11) and bolt (13) that hold it. Tighten bolt (13) to a torque of 38.0 1.5 N m (28 1 lb ft).18. Put gasket (2) and cover (14) in position on water pump housing (18), and install the two washers and bolts (1) that hold them.19. Install bearing (12) on gear (10) with a press.20. Position gear (10) and bearing (12) as a unit on shaft (9). Install the washer and bolt (15) that hold them together. Tighten bolt (15) to a torque of 97 7 N m (72 5 lb ft).End By:a. install water pump