20496257 Volvo.Penta Plug

1. Drain the coolant from the engine.2. Remove clips (4) and disconnect hose (5).3. Put a pry bar in the belt tightener to release the pressure on belts (3). Carefully release the belt tightener because it is under spring tension.4. Remove bolts (1), unhook spring (2) and remove belt tightener (6). 5. Disconnect harness (11) and remove clip (16).6. Disconnect hoses (8), (9), (10) and (14).7. Remove elbow (7) and cover (12).8. Remove two bolts (13) and disconnect bonnet (15). 9. Remove all long bolts (18) to remove water pump (17). For installation of the water pump, reverse the procedures of Steps 1 through 9.Disassemble Water Pump
Start By:a. remove water pump The water pump seal can be replaced without removing the water pump from the engine.An intermittent leakage of a small amount of coolant from the hole in the water pump housing is not an indication of a water pump seal failure. This is required to provide lubrication for the seal. Replace the waterpump seal only if a large amount of leakage or a constant flow of coolant is observed draining from the water pump housing.1. Remove O-ring seal (1) from the adapter.2. Remove adapter (2) from the housing. Remove the O-ring seal from the outside diameter of the adapter.3. Remove bolt (3) and the retainer that hold the impeller on the shaft. 4. Use tooling (A) to remove impeller (4) from the shaft. 5. Remove the spring and seal (5) from the shaft. 6. Remove four bolts (7) from retainer (6) that hold the shaft assembly to the pump housing.7. Remove O-ring seal (8) from the housing. 8. Remove gear and shaft assembly (10) from the housing.9. Remove bolt (9) and the retainer from the shaft assembly. 10. Use a press to remove the shaft assembly from gear (11). Remove the retainer from the shaft assembly. 11. Remove bearing (13), spacer (14) and bearing (12) from the shaft. 12. Remove lip-type seal (15) from the housing.13. Turn the housing over, and remove ceramic ring (16) and the seal.Assemble Water Pump
1. Use 6V1541 Quick Cure Primer and clean shaft (8) and the seal counterbore in the pump housing.2. Install bearing (4), spacer (3) and bearing (2) on shaft (8).3. Put retainer (1) and gear (7) in position on the shaft assembly. Install retainer (6) and bolt (5). 4. Use tooling (A) to install the lip seal in the housing as shown. Put a small amount of clean SAE 30 oil on the lip of the seal. 5. Install a new O-ring seal (10) on the housing.6. Put shaft assembly (9) in position in the housing. Install the bolts that hold the retainer to the housing.
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.
7. Put ceramic ring (12) in position in rubber seal (11). Use hand pressure and tool (B) to install the ceramic ring 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.8. Remove the spring from seal assembly (13). Use hand pressure and tool (B) to install the seal assembly. Push the seal assembly on the shaft until the seal faces make light contact. 9. Install spring (15) on the shaft.10. Put impeller (14) in position on the shaft. Install the washer and bolt that holds it. Tighten the bolt to a torque of 39 3 N m (29 2 lb.ft.). 11. Install O-ring seal (17) on the outside diameter of the adapter. Put a small amount of clean SAE 30 oil on the O-ring seal.12. Install O-ring seal (18) on the adapter.13. Put adapter (16) in position on the housing.End By:a. install water pump