981245 Volvo.Penta Plug

1. Disconnect water inlet line from the auxiliary water pump (2).2. Disconnect water outlet tube (1) at the fittings on the auxiliary water pump (2) and the aftercooler housing. Remove tube (1). 3. Remove bolts (3), auxiliary water pump (2) and gasket from the accessory drive housing.Install Auxiliary Pump (Fresh Water)
1. Install a new gasket on the accessory drive housing (1).2. Put auxiliary water pump (2) into position over dowels and fasten with the bolts. 3. Put water outlet tube (3) into position and fasten to the fittings on the auxiliary water pump and aftercooler housing.4. Connect inlet water line to the auxiliary water pump.Disassemble Auxiliary Pump (Fresh Water)
start by:a) remove auxiliary pump (fresh water) 1. Remove elbow (2) and pipe nipple from housing (1). Put identification on body (4) and housing (1) for use at assembly.2. Remove nuts (3) lockwashers, body (4) and gaskets from housing (1). 3. Remove nut (5), washer and gear (6) from the shaft. 4. Remove key (7) and spacer (8) from the shaft. 5. Use tool (A) and remove snap ring (9). 6. Remove the locknut that holds impeller (11) in place.7. Install a 3/8"-24 NF jam nut (10) even with the end of the shaft.8. Put body (4) in position in a press. Use tooling (B) and press as shown to loosen impeller (11) on the shaft. 9. Remove jam nut (10) and impeller (11) from the shaft. 10. Remove spring (12). 11. Remove key (14), shims and seal assembly (13). 12. Turn pump body (4) over and remove shaft (15) and bearings as a unit. 13. Use tool (C) and remove snap ring (16) from shaft (15). 14. Put shaft (15) and bearings (17) into position in a press on tool (D). Use the press to push shaft (15) from bearings (17) and spacer. 15. Remove ceramic ring (18) and seal. 16. Remove slinger (19). 17. Remove seal (20) from the body (4).Assemble Auxiliary Pump (Fresh Water)
1. Install lip seal (1) in body (2) with tooling (A). Install lip seal even with bottom of bearing bore with the lip of the seal toward the bearings. Put a small layer of engine oil on the lip of the seal. 2. Put slinger (3) in position above the lip type seal.
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.
3. Put the ceramic ring (4) in position in the rubber seal. Use a cover for protection to install the ceramic ring. Install the ceramic ring evenly with hand pressure. 4. Install snap ring (5) on shaft (6) with tool (B). 5. Heat bearings (7) and (9) to a maximum temperature of 275°F (135°C).6. Install bearing (9) on shaft (6) against the snap ring.7. Install spacer (8) and bearing (7). Make sure bearing (7) is in full contact with the spacer. Make sure when shaft (6) is installed in body (2), that the slinger is in the correct position on the shaft. 8. Install shaft (6) and bearings in body (2) through the slinger. 9. Install snap ring (10) that holds the shaft assembly in place with tool (C). 10. Install key (12) in the shaft.11. Put spacer (11) in position over the shaft. 12. Install gear (13), washer and locknut. Tighten the locknut to a torque of 45 5 lb.ft. (60 7 N m).
Use clean water only as a lubricant for assembly. Do not damage or put hands on the wear surface of the carbon ring or the ceramic ring.
13. Install carbon ring seal assembly (15) over the shaft. Push carbon ring seal assembly on the shaft until seal faces make light contact.14. Put original thickness of shims (14) on the shaft. 15. Install key (17) in the shaft.16. Put spring (16) in position on the carbon ring seal assembly. 17. Install impeller (18) and locknut. Tighten the locknut to a torque of 30 5 lb.ft. (40 7 N m). 18. Check clearance (X) between the body (2) and the impeller (18). The clearance must be .005 to .015 in. (0.13 to 0.38 mm). If necessary add or remove shims (14) behind the impeller. 19. Put gaskets (20) in position on the body. Make an alignment of identification marks put on at disassembly and install housing (19). 20. Measure the clearance (Y) between the impeller (18) and the inside of housing (19). The clearance between the impeller and housing must be .015 to .030 in. (0.38 to 0.76 mm). If necessary, add or remove gaskets (20) between the body and housing. 21. Put 5P3413 Pipe Sealant on the threads of the pipe nipples on elbow (21). Install elbow (21) and pipe nipples in housing (19).end by:a) install auxiliary pump (fresh water)