Volvo Cars 1999-05

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Spark plug cover
     
    Fuel line clips
     
    Expansion tank
     
    Accessory drive belts
     
    Vibration damper guard
     
    Front wheel
     
    Inner fender panel
     
    Front timing cover
     
    Timing belt
     
    Water pump
     

  6.  

To install:

  1. Install or connect the following:

    Water pump with a new gasket. Tighten the bolts to 15 ft. lbs. (20 Nm).
     
    Timing belt
     
    Front timing cover
     
    Inner fender panel
     
    Front wheel
     
    Vibration damper guard
     
    Accessory drive belts
     
    Expansion tank
     
    Fuel line clips
     
    Spark plug cover
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the timing belt.
  6.  
  7. Securely attach a lifting device to the engine and raise it slightly to access the top two bolts of the water pump.
  8.  
  9. Lower the engine and remove the remaining bolts.
  10.  
  11. Gently tap the pump wheel with a mallet to remove.
  12.  

To install:

  1. Using a new pump and gasket, tighten the bolts alternately to 13 ft. lbs. (17 Nm).
  2.  
  3. Install the timing belt.
  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

4-Cylinder Engines



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Accessory belt
     
    Timing belt cover
     
    Timing belt
     
    Water pump
     

  6.  

To install:



Click image to see an enlarged view

Fig. Water pump and gasket

Water pump and gasket

Click image to see an enlarged view

Fig. Water pump installation

Water pump installation
  1. Install or connect the following:

    Water pump with a new gasket. Tighten bolts to 13 ft. lbs. (17 Nm).
     
    Timing belt
     
    Timing belt cover. Tighten bolts to 9 ft. lbs. (12 Nm).
     
    Accessory belt
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Accessory belt
     
    Timing belt cover
     
    Timing belt
     
    Water pump
     

  6.  

To install:

Click image to see an enlarged view

Fig. Water pump and gasket

Water pump and gasket

Click image to see an enlarged view

Fig. Water pump installation

Water pump installation

  1. Install or connect the following:

    Water pump with a new gasket. Tighten bolts to 13 ft. lbs. (17 Nm)
     
    Timing belt
     
    Timing belt cover. Tighten bolts to 108 inch lbs. (12 Nm)
     
    Accessory drive belt
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

6-Cylinder Engines



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Water pump
     

  6.  

To install:

  1. Install or connect the following:

    Water pump with a new gasket. Tighten bolts to 13 ft. lbs. (17 Nm).
     
    Timing belt
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Water pump
     

  6.  

To install:

  1. Install or connect the following:

    Water pump with a new gasket. Tighten bolts to 13 ft. lbs. (17 Nm)
     
    Timing belt
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

Rear Wheel Drive



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belts
     
    Front cover
     
    Timing belt
     
    Water pump
     

  6.  

To install:



Water pump with a new gasket. Tighten the bolts to 15 ft. lbs. (20 Nm).
 
Timing belt
 
Front cover
 
Accessory drive belts
 
Negative battery cable
 

  1. Fill the cooling system.
  2.  
  3. Start the engine and check for leaks.
  4.  

Except Rear Wheel Drive



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Spark plug cover
     
    Fuel line clips
     
    Expansion tank
     
    Accessory drive belts
     
    Vibration damper guard
     
    Front wheel
     
    Inner fender panel
     
    Front timing cover
     
    Timing belt
     
    Water pump
     

  6.  

To install:

  1. Install or connect the following:

    Water pump with a new gasket. Tighten the bolts to 15 ft. lbs. (20 Nm).
     
    Timing belt
     
    Front timing cover
     
    Inner fender panel
     
    Front wheel
     
    Vibration damper guard
     
    Accessory drive belts
     
    Expansion tank
     
    Fuel line clips
     
    Spark plug cover
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

5-Cylinder Engines



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine stabilizer brace
     
    Servo reservoir
     
    Expansion tank
     
    Accessory belt
     
    Front timing belt cover
     
    Front wheel
     
    Inner fender panel
     
    Timing belt
     
    Water pump
     

  6.  

To install:

  1. Install or connect the following:

    Water pump with a new gasket. Tighten bolts to 13 ft. lbs. (17 Nm)
     
    Timing belt
     
    Front timing belt cover. Tighten bolts to 108 inch lbs. (12 Nm)
     
    Accessory belt
     
    Servo reservoir
     
    Expansion tank
     
    Engine stabilizer brace. Tighten the bolts at suspension turrets to 37 ft. lbs. (50 Nm). Tighten bolt for engine bracket to 59 ft. lbs. (80 Nm)
     
    Inner fender panel
     
    Front wheel
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

 
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