Volvo Penta 2003 fresh water cooling circuit leak

[eladn]

Hi there,

As the title suggest - I have a water leak from the fresh water cooling circuit on an old VP 2003. The leak is on the coolant T pipe (copper?) connecting the expansion tank and the pump/heat exchanger.
If you look at the attached drawing - it is at the point where o-ring 21 is located (for some reason the line connecting this point to the heat exchanger is missing in the drawing).

I have purchased the replacement o-ring, only to see that if I follow the workshop manual, it seems like the whole cooling system would essentially have to come off for this to be exchanged?
The pipes have a bit of a wiggle, but would it be enough to force it out without having to take off most of the other parts?
If I otherwise understand correctly, both the pump and the pipes leading to the pump at the front of the engine would have to come off then?

Many thanks!

 

[FulmarJeddo]

I wouldn’t advise forcing the pipe. I have a raw water cooled VP 2002 and had a leaking pump. I got a bit heavy handed with one of the copper pipes connecting to the water pump. I found I could only stop the joint from leaking by getting the pipe to exactly align with the fitting. If you bend a pipe to get it apart, you will probably struggle to straighten the pipe when reassembling.

 

[pvb]

It's important to realise that there are various sizes of sealing rings in the Volvo Penta engines. The only way to be sure you have the correct one is to check the part number on the diagram. Don't be tempted to bend the pipes in any way.

 

[Bilgediver]

Looks like you remove the pump so will need to replace a number of seal rings. With the pump out of the way the T pipe should come clear.

 

[JimGlass]

Similar problem after removing pipes to replace starter motor. What a dog’s dinner! Eventually, yep, it’s a new Betamarine. Nuts, I know but that’s how impossible I was finding it. Hope you managed better than me!