859620 Volvo.Penta Repair kit

At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water or steam. Any contact can cause severe burns. Look at the sight gauge to check the coolant level. The coolant level should be in the green range. If necessary, remove the fill cap only after the engine has been stopped and the cap is cool enough to remove with your bare hand. Remove the cooling system fill cap slowly to relieve pressure. Cooling system condition contains alkali that can cause personal injury. Avoid contact with the skin and eyes and do not drink. Allow cooling system components to cool before draining.
Put identification on all lines, hoses, wires and tubes for installation purposes. Cap and plug all lines, hoses and tubes to prevent foreign material from entering the system. Drain all fluids in a suitable container for storage or disposal. 1. Drain the engine coolant.2. Loosen bolts (4) and remove water pump drive belt (1).3. Loosen clamp (2) and remove loser radiator hose (3) from the water pump. 4. Loosen clamp (5) and remove the upper hose from the water pump.5. Remove bolts (6) and (7) and remove compressor mounting bracket (8) from the water pump. 6. Disconnect the wire connector from temperature sensor (9).7. Remove bolts (10) and remove the water pump from the engine.End By:a. install right engine guard Refer to the Operation & Maintenance Manual for all fluid capacities and the proper filling procedures.Disassemble & Assemble Water Pump
Start By:a. remove water pump 1. Remove valve assembly (1) and temperature sensor (2) from water pump (4).2. Remove O-ring seals (3). 3. Remove bolts (9) and washers (8) from cover (7).4. Remove cover (7) and gasket (12).5. Remove plug (10) and O-ring seal (11) from cover (7).6. Remove impeller (13) from shaft assembly (17).7. Remove seal assembly (14) from shaft assembly (17).8. Remove shaft assembly (17) from pump housing (15).9. Remove pulley (18) fro shaft assembly (17).10. Remove plug (5) and O-ring seal (6) from pump housing (15).11. Remove filter (16) from pump housing (15). The following steps are for the assembly of the water pump.12. Install filter (16) in pump housing (15). Filter (16) should not extend beyond the surface of the pump housing.13. Install plug (5) and O-ring seal (6).14. Install pulley (18) on shaft assembly (17).15. Install shaft assembly (17) in pump housing (15).
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.
16. Install seal assembly (14) over shaft assembly (17) and in pump housing (15).17. Install impeller (13) on shaft assembly (17). Use a feeler gauge to maintain a clearance of 0.75 0.25 mm (.03 .01 in) between impeller (13) and the face surface of pump housing (15).18. Install gasket (12) and cover (7) with bolts (9) and washers (8).19. Install plug (10) and O-ring seal (11).20. Install O-ring seals (3).21. Install valve assembly (1) and temperature sensor (2) in water pump (4).End By:a. install water pump