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

Power Steering Pump

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REMOVAL & INSTALLATION



240 Series, 700 Series and Coupe
  1. Disconnect the negative battery cable.
  2.  
  3. Remove all dirt and grease from around the line connections at the pump.
  4.  
  5. Using a container to catch any fluid that might run out, disconnect the power steering lines and plug them to prevent dirt from entering the system.
  6.  
  7. Remove the tensioner locking screws on both sides of the pump and remove the drive belt.
  8.  
  9. Turn the pump up and remove the three bolts holding the bracket to the engine block.
  10.  
  11. Remove the pump and bracket.
  12.  
  13. If the pump is being replaced with a new one, remove the nut and pulley from the old pump and transfer it to the new one. Separate the bracket and tensioner from the pump and install them loosely on the new pump.
  14.  

To install:
  1. Place the pump in position on the engine and install the retaining bolts and spacer. tighten the bolts to 18 ft. lbs. (25 Nm).
  2.  
  3. Install the drive belt.
  4.  
  5. Adjust the belt tension and then tighten the nuts of the long bolts.
  6.  
  7. Use new copper washers, and reconnect the fluid lines to the pump.
  8.  
  9. Fill the reservoir with Type A or Dexron®III automatic transmission fluid and bleed the system.
  10.  
  11. Connect the negative battery cable.
  12.  

940, 960, S90 and V90 Series
  1. Disconnect the negative battery cable.
  2.  
  3. Loosen the belt tensioner.
  4.  
  5. Remove the mounting bracket and bolt.
  6.  
  7. Disconnect the lines at or near the pump. Depending on the type of pump, it may be necessary to disconnect the rubber hoses from the metal pipes instead of removing the lines at the pump body. Use a catch pan under the vehicle for spillage. Plug the lines and fittings immediately to avoid contamination.
  8.  
  9. Remove the large retaining bolt and remove the drive belt from the pump.
  10.  
  11. Lower the pump slightly and disconnect the filler hose from the pump.
  12.  
  13. Remove the pump from the vehicle.
  14.  

To install:
  1. If the pump is to be replaced with a new one, transfer the pulley, the mounting bracket and the washers to the new pump.
  2.  
  3. Install the mounting bracket on the new pump; make sure the thick washer is between the bracket and the pump body.
  4.  
  5. Install the pulley with the conical face of the washer must be to the outside.
  6.  
  7. Connect the filler hose to the pump.
  8.  
  9. Position the pump and install the retaining bolts loosely.
  10.  
  11. Install the mounting bracket and belt.
  12.  
  13. Adjust the belt tension.
  14.  
  15. Tighten the lower retaining bolts to 18 ft. lbs. (25 Nm).
  16.  
  17. Connect the fluid hoses to the pump. Use new copper washers and/or hose clamps. Tighten the banjo fittings to 31 ft. lbs. (40 Nm).
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Fill the fluid reservoir and start the engine.
  22.  
  23. Bleed the steering system.
  24.  

850, C70, S70 and V70 Series
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the radiator reservoir cap.
  4.  
  5. Open the radiator draincock on the left side under the radiator and drain out about 3.2 qts. (3 liters) of coolant.
  6.  
  7. Disconnect the radiator hose from the thermostat housing.
  8.  
  9. Remove the oil hose holder from the dipstick tube and the air cooler hose from the control module box.
  10.  
  11. Using the proper sized ratchet, release the tension from the drive belt tensioner and remove the belt from the power steering pump.
  12.  
  13. Remove the long bolt and spacer from the plate.
  14.  
  15. Loosen the pressure side hose a quarter turn and the lower plate mount nut a few turns.
  16.  
  17. Remove all of the pump mounting bolts.
  18.  
  19. Lift the pump straight up and disconnect the pressure hose and old O-ring. Collect any fluid that spills.
  20.  
  21. Carefully make a small cut in the end of the return line no longer than the mark on the hose itself.
  22.  
  23. Remove the pump.
  24.  
  25. Raise and safely support the vehicle.
  26.  
  27. Turn the steering wheel from lock to lock and collect the fluid from the lines. Make sure no oil gets into the alternator.
  28.  
  29. Place the old pump in a vise and remove the pulley using an appropriate puller.
  30.  

To install:
  1. Install the pulley on the new pump, using an appropriate pressing tool. Apply a small amount of oil to the shaft to ease the installation.
  2.  
  3. Install the pump and five mounting bolts, tighten them to 18 ft. lbs. (25 Nm).
  4.  
  5. Install the long bolt and cover plate spacer, tighten it to 18 ft. lbs. (25 Nm).
  6.  
  7. Tighten the lower attachment to 18 ft. lbs. (25 Nm).
  8.  
  9. Install the following:

    Pressure hose with a new O-ring
     
    Return hose
     
    Hose bracket for power steering hoses to dipstick tube
     
    Radiator hose
     
    Pump drive belt
     
    Cooling hose to the control module box.
     

  10.  
  11. Connect the negative battery cable.
  12.  
  13. Fill the cooling system with coolant.
  14.  
  15. Fill the power steering pump reservoir with new fluid.
  16.  
  17. Bleed the steering system.
  18.  

BLEEDING



See Figures 1, 2 and 3

  1. Fill the reservoir with the proper type of fluid.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Place the transmission in N and apply the parking brake.
  6.  
  7. Start the engine and fill the reservoir as the level drops.
  8.  
  9. When the reservoir level has stopped dropping, slowly turn the steering wheel from lock to lock several times. Fill the reservoir if necessary.
  10.  
  11. Continue to turn the steering wheel slowly until the fluid in the reservoir is free of air bubbles.
  12.  
  13. Stop the engine and observe the oil level in the reservoir. If the oil level rises more than 1 / 4 in. (6mm) past the level mark, air still remains in the system. Continue bleeding until the level rise is correct.
  14.  
  15. Lower the vehicle.
  16.  

 
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