Volvo 240/740/760/780/940/960 1990-1998

Water Pump

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REMOVAL & INSTALLATION



2.3L 4-Cylinder Engine

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Set the heater control to MAX heat.
  4.  
  5. Remove the expansion tank cap.
  6.  
  7. Open the draincocks on the right-hand side of the engine block and on the radiator, and drain the coolant into a suitable container.
  8.  
  9. Close the draincocks when the coolant is completely drained.
  10.  
  11. Remove the radiator shroud and fan.
  12.  
  13. Remove the lower radiator hose at the water pump.
  14.  
  15. If required, remove the retaining bolt for the coolant pipe beneath the exhaust manifold and pull the pipe rearward.
  16.  
  17. Remove the drive belts and water pump pulleys.
  18.  
  19. Remove the water pump bolts, washers and nuts.
  20.  
  21. Remove the water pump assembly.
  22.  

To install:
  1. Clean the gasket contact surfaces thoroughly and use a new gasket and O-rings. Coat the O-rings with coolant prior to installing them. Install a thin layer of gasket sealer on the water pump to help the gasket stay in place during installation.
  2.  


CAUTION
Make sure that the water pump is aligned before tightening the retaining bolts, it is extremely easy to misalign the pump and break it.

  1. Install the water pump and tighten the bolts to 11-15 ft. lbs. (15-20 Nm) in a crisscross pattern.
  2.  
  3. Install the coolant pipe and lower radiator hose.
  4.  
  5. Install the accessory drive belts and water pump pulley.
  6.  
  7. Install the fan and shroud.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Fill the cooling system with coolant.
  12.  
  13. Start the engine and allow it to reach normal operating temperature.
  14.  
  15. Check for leaks.
  16.  
  17. Add coolant as necessary.
  18.  



Click image to see an enlarged view

Fig. Fig. 1: Water pump installation on the 2.3L 4-cylinder

2.8L 6-Cylinder Engine

See Figure 2

  1. Disconnect the negative battery cable.
  2.  

On some variants of this engine, it may be necessary to remove the front and main sections of the intake manifold.

  1. Remove the overflow tank cap and drain the cooling system.
  2.  
  3. Disconnect both radiator hoses.
  4.  
  5. On automatic transmission vehicles, disconnect the transmission cooler lines at the radiator.
  6.  
  7. Disconnect the fan shroud.
  8.  
  9. Remove the radiator and fan shroud.
  10.  
  11. Remove the fan.
  12.  
  13. Remove the hoses from the water pump to each cylinder head.
  14.  
  15. Remove the fan belts.
  16.  
  17. Remove the water pump pulley.
  18.  
  19. Loosen the hose clamps at the rear of the water pump.
  20.  
  21. Remove the water pump from the block (3 bolts).
  22.  

To install:
  1. Transfer the thermal sender and temperature sensor to the new water pump.
  2.  
  3. Transfer the thermostat cover, thermostat and rear pump cover to the new pump.
  4.  
  5. Install the new pump and tighten the bolts to 11-15 ft. lbs. (15-20 Nm).
  6.  
  7. Install the clamps, water pump pulley and fan belts.
  8.  
  9. Install the hoses that reach to each cylinder head.
  10.  
  11. Install the fan, shroud and radiator.
  12.  
  13. If equipped with an automatic transmission, connect the transmission cooler lines.
  14.  
  15. Install the intake manifold, as necessary.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Fill the radiator with coolant if necessary.
  20.  
  21. Start the engine and allow it to reach operating temperature.
  22.  
  23. Check for leaks.
  24.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the water pump assembly on the 2.8L 6-cylinder engine

2.9L 6-Cylinder Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system by opening the draincock on the right side of the cylinder block.
  4.  
  5. Remove the timing belt.
  6.  
  7. Remove the water pump retaining bolts (7) and remove the water pump.
  8.  

To install:
  1. Before installing the water pump, clean the mating surfaces.
  2.  
  3. Install the water pump, using a new gasket.
  4.  
  5. Tighten the mounting bolts to 15 ft. lbs. (20 Nm).
  6.  
  7. Install the timing belt.
  8.  
  9. Fill the cooling system.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Start the engine and check for leaks.
  14.  

2.3L and 2.4L 5-Cylinder Engines

See Figures 3, 4 and 5

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and safely support vehicle.
  6.  
  7. Remove the splashguard from below the engine.
  8.  
  9. Drain the cooling system.
  10.  
  11. Remove the following:

    Fuel line clips
     
    Expansion tank
     
    Front timing cover
     
    Accessory belts
     

  12.  
  13. Remove the timing belt.
  14.  
  15. Remove the water pump retaining bolts and remove the water pump from the block.
  16.  
  17. Clean the cylinder block where the two mate.
  18.  

To install:

The replacement pump may look different than your original, this is normal as Volvo redesigned the pump on later models and the replacement pump is the new design.

  1. Install the new water pump and gasket, and tighten the bolts to 15 ft. lbs. (20 Nm).
  2.  
  3. Install the timing belt.
  4.  
  5. Install the following:

    The two fuel line clips
     
    Front timing cover
     
    Accessory belts
     
    Spark plug cover
     
    Vibration damper guard
     
    Wheel well panel
     
    Wheel
     

  6.  
  7. Connect the negative battery cable.
  8.  
  9. Fill the cooling system.
  10.  
  11. Run the engine to normal operating temperature.
  12.  
  13. Top off as necessary and check for leaks.
  14.  



Click image to see an enlarged view

Fig. Fig. 3: The water pump is retained by eight bolts (some are hidden in photo)



Click image to see an enlarged view

Fig. Fig. 4: Unfasten the retaining bolts and carefully remove the water pump from the engine



Click image to see an enlarged view

Fig. Fig. 5: Position a new gasket on the pump before installing it

 
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