850200 Volvo.Penta Toggle switch

1. Drain the coolant from the aftercooler radiator tank. 2. Disconnect tube (3) from elbow (1) and disconnect elbow (1) from the water pump.3. Disconnect tube (4) from elbow (2). Loosen hose clamp (5).4. Remove bolts (6), clip (8) and elbow (2) from the water pump.5. Disconnect hose (7) from the water pump. 6. Install tooling (A) on water pump (9) and fasten a hoist. Remove bolts (10) and remove auxiliary water pump (9). The weight of the water pump is 32 kg (70 lb.). 7. If bearing (11) must be replaced, remove the air compressor. Refer to the topic "Remove the Air Compressor" in this module for further information.8. Remove two bolts (12) and adapter (13). Use tooling (B) and remove bearing (11) from adapter (13). The following steps are for installation of the auxiliary water pump.9. Install the auxiliary water pump in the reverse order of removal.10. If bearing (11) was removed, align the hole in the bearing with the oil hole in adapter (13). Use tooling (B) and install the bearing until it is 1.5 0.5 mm (.06 .02 in.) below the rear surface of adapter (13). After installation, the inside diameter of bearing (11) must be 75.000 0.055 mm (2.9528 .0022 in.)11. Lubricate bearing (11) and the O-ring seal on adapter (13) and water pump (9) with clean engine oil before installation.Disassemble Auxiliary Water Pump (Aftercooler)
Start By:a. remove auxiliary water pump (aftercooler) 1. Remove O-ring seals (3) and (4) from the pump housing.2. Remove the bolts and gear (2) from shaft (1). 3. Remove the bolts and adapter (5) from the pump housing. Remove the O-ring seal from adapter (5). 4. Loosen bolt (6) holding impeller (7) to the shaft.5. Use tooling (A) to loosen impeller (7) from the pump shaft. Remove tooling (A). Remove the washer, bolt (6), and impeller (7) from the pump shaft and housing. 6. Remove spring (9) from carbon seal assembly (10). Remove carbon seal assembly (10) from the end of shaft (8). 7. Remove the bolts that hold retainer washers (12) to the pump housing. Remove shaft (1) and washers (12) from the pump housing. 8. Remove the bolts that hold the shims and retainer washers (13) to the pump housing. Remove shaft (8), the shims and washers (13) from the pump housing.9. Remove the rubber ring and ceramic seal (11) from the pump housing. 10. Remove lip-type seal (14) from the pump housing. 11. Remove bearing (15) from the pump housing.Assemble Auxiliary Water Pump (Aftercooler)
When installing bearing (15) make sure the lubrication hole in the bearing is aligned with the oil passage in the pump housing.
1. Position bearing (15) on the pump housing making sure the oil passages are in aligned. Use tool group (A) and a press to push the bearing into the pump housing until. Bearing (15) should be 1.5 0.5 mm (.06 .02 in.) below the surface of the pump housing. The inside diameter of the bearing must be 75.000 0.055 mm (2.9528 .0022 in.). 2. Position seal (14) into the pump housing. Make sure the lip of seal (14) faces toward bearing (15) as shown. Install seal (14) with a press and tooling (A). Use clean engine oil to lubricate seal (14). 3. Install shaft (8) in the pump housing. Install the shims, bolts and retainer washers (13). 4. Lubricate bearing (15) with clean engine oil. Install shaft (1) and retainer washers (12). Install the bolts into retainer washers (12).
Use clean water as the only lubricant when installing seal group into the pump housing. Use care when handling the seal group during installation. Touching the wear surfaces of the carbon or ceramic rings can cause contamination or damage. Install the smoothest face of the ceramic ring toward the carbon seal assembly.
5. Install ceramic ring (11) into the rubber seal. Lubricate ceramic ring (11) with water. Use hand pressure and tool (B) to install the seal and seal ring into the housing as shown. 6. Remove spring (9) from carbon seal assembly (10). Put clean water on the inside diameter of the seal for lubrication. Use hand pressure and tool (B) to push carbon seal (10) onto shaft (8) until the faces of seals (11) and (10) make contact. 7. Install spring (9) into carbon seal (10). 8. Put impeller (7) in position on the pump shaft as shown. 9. Install the bolt and washer that hold impeller (7) to the pump shaft. Tighten the bolt to a torque of 38 4 N m (28 3 lb. ft.). 10. Install the O-ring seal onto adapter (5). Use clean engine oil to lubricate the O-ring seal.11. Install adapter (5) onto the pump housing. 12. Put gear (2) in position on shaft (1). Install the bolts to hold gear (2). 13. Install O-ring seals (3) and (4). Lubricate the O-ring seals with clean engine oil.End By:a. install auxiliary water pump (aftercooler)