Volvo 2001 - Fresh-Water Cooling 2002, 2003; Cooling System Installation Procedures

FRESHWATER COOLING 2002, 2003
Pos 21 and23 are for hot water outlet .
1 .

Fit the circulation pump (complete with tensioner bracket and spacer sleeve,
position
4) . Tighten
the bolts (M8x75) to
20 Nm (2,0 kpm)
(14 .7 ft .lbs), position 1 .
2 .

Suspend the heat exchanger loosely by the rear bolt (M8x16and
spring washer .), position 5 .
a) Fit the pipe (position 6) and the hose (position 3) between the heat exchanger and the sea-water pump, using
double hoseclamps (apply soapy water to the rubber rings, applies
for all rubber rings) .
b) Fit the pipe between the
heat-exchanger and thermostat housing, position 7 .
c)
Fit the pipe between the heat-exchanger and the circulation pump, position
8 .
3 .

Locatethe pipes in the heat-exchanger
andanddraw it forward tightening it with the two bolts (M8x16and
spring
washers), positions 5and 9 .
4 .

Fit the pipe between the heat-exchanger and the exhaust elbow, position 10 .
NOTE! The holderforthe pipe, (position
11) and the lock (position
11
a) .
5 .

Fit the pipe between the circulation pump (lower outlet) and the cylinder
head, position 12 .
6 .

Fit the pipe between the
circulation pump (upper outlet) and the cylinder head, position 13 .
7 .

Fit the alternator, place the bolt for the tensioner bracket with the head
forwards . Put onand tension the V-belt .
8 .

Fit the expansion tank to the
exhaust elbow, position 15 .
9 .

Fit the hose between the tank and the circulation pump (double pipe ) 2002
= 450 mm (17 .7 in), 2003 = 550 mm (21 .7
in) (only single hose clamps are
used on the fresh-watersystem), position 16 .
10 .

Fit the nipple, position 17 .
11 .

Fitthe hose between the tank and the thermostat housing (nipple 17) : 2002 = 350
mm (13
.8
in), 2003 = 450 mm (17 .7
in), position 18 .
12 . Fit the plugs in the exhaust elbowand the cylinder head, positions 19 and 20 .
13 .

Fill the system to the right level
with
a
mixture of fresh water (50%
)
and anti-freeze
(50%),
altematively rust-protection
additive (VP accessory) . The fresh-water system volumes : 2002 = 4.0 dm2 (litre) (0.88 Imp. gals) (1.1 US gals),
2003 = 5 .5 dm 3 (litre) (1 .2 Imp . gals) (1
.45 US gals) .