Volvo Penta 2002 Instrucciones De Montaje página 4

Freshwater cooling.
WARNING! There is a risk of water penetra-
tion when working on the seawater system.
Turn of the engine and close the sea cock be-
fore starting work.
1. Close seawater inlet.
2. Drain water from engine.
3. Rinse the engine in fresh water if it has been
used in salt water.
4. Dismantle the tensioning bracket and v-belt of
the generator.
5. Move the generator up out of the way (lock in
the raised position).
6. Remove two screws and washers in the trans-
mission covers (under the generator bracket),
pos 1.
7. Remove the plug from the cylinder head (under
thermostat housing), pos 2.
8. Remove the hose between the seawater pump
and the cylinder head and also the upper pipe
(not to be used later). Cut the existing hose to
75 mm length, pos 3.
9. Fit the circulator pump (complete with tensio-
ning bracket and spacer). Tighten the screws
(M8x75) at a torque of 20 Nm (2 Kpm), pos 4.
10. Dismantle the thermostat housing, the pipe bet-
ween the thermostat housing and the exhaust
pipe bend and the cylinder head.
11. Exchange the thermostat (N.B. new sealing
ring) and fit the thermostat housing.
12. Fit the two brackets (pos 9) loosely round the
heat exchanger (pos 5) with 2 flange screws
and 2 flange nuts. Hang up the heat exchanger
loosely with two similar screws.
a) Fit the pipe (pos 6)*) and the hose (pos 3)
between the heat exchanger and the seawater
pump; use the existing hose clamps (smear so-
apy water on all of the rubber rings).
b) Fit the pipe between the heat exchanger and
thermostat housing, pos 7.
c) Fit the pipe between the heat exchanger and
the circulation pump, pos 8. Insert the pipe into
the heat exchanger and adjust to best position.
Screw tight with the four screws on the heat
exchanger.
13. Fit the pipe between the heat exchanger and
the exhaust pipe bend, pos 10 (2002= short
pipe, 2003= long pipe). Note: the bracket for
the pipe, pos 11, and new clamp, pos 11a.
14. Fit the pipe between the circulation pump (lo-
wer outlet) and the cylinder block, pos 12.
15. Fit the pipe between the circulation pump (up-
per outlet) and the cylinder head, pos 13.
16. Fit the generator; fit the screw for the bracket
with the head turned outwards. Place a new
V-belt in position and tension the belt.
17. Mount the expansion tank on a bulkhead or
similar. The tank should not be placed so low
that the bracket is under the upper part of the
cylinder head, pos 14 and 15.
18. Fit the hose between the tank and the circula-
tion pump (branch pipe). Only single hose clips
on the freshwater section, pos 16.
19. Remove the plug from the thermostat housing
and fit the connector, pos 17.
20. Fit the hose (pos 18) between the tank and the
thermostat housing (connector). Clip the hoses
into position using soft clip.
21. Fit plugs in to the exhaust pipe bend and the
cylinder head, pos 19 and 20.
22. Fill the system to the correct level with a mixtu-
re of fresh water (50%), and ethylene glycol
(50%), or alternatively an anti-corrosion agent
(VP accessory). Volume of freshwater system:
2002= 4,0 dm 3 (litre), 2003= 5,5 dm
Open the seawater intake.
Hot water outlet.
1. Remove the plug on the circulation pump and fit
the hose connector (3/8"-18 NPTF), pos 21.
2. Remove the zinc plug from the cylinder head,
pos 22, and fit the hose connector (1/2"-14
NPTF), pos 23.
The arrows on the connectors indicate the di-
rection of flow of the water. The recommended
volume of water for heating is approx. 20 litre.
The recommended hose dimension is 16x4 (5/
8-x5/32"). When there is a large consumption
of hot water (long heating time) the system
should be supplemented by a thermostat, 60°
(hose thermostat) at the outlet connector, pos
24.
Note: The upper edge of the hot water heater
should not be placed higher than the "min" mar-
king on the expansion tank.
IMPORTANT! Run the engine warn after the instal-
lation is finished. Make sure that there are no lea-
kages. Check and retighten all hose clamps.
*) The kit includes a 90° hose connector. This should be used for
fitting the vacuum valve for freshwater cooling and in this case,
replaces the pipe shown in pos 6.
3 (litre).